# Patent

## Title
Process for the manufacture of a blank for a container

## Abstract

This is a division of application Ser. No. 295,979 filed Aug. 25, 1981, now Pat. No. 4,422,230 which is in turn a continuation of Application Ser. No. 123,231 filed Feb. 21, 1980, now abandoned.

## Background
1. Field of the Invention

This invention relates to a method for preparing a female mold for forming a head model for a wig, and more particularly to a method for preparing a female mold to be used for forming a head model which is employable for preparation of a wig base or as a workbench for a wig.

2. Description of Prior Art

In accordance with a known method, a wig base is prepared by employing a flexible synthetic resin sheet such as a vinyl sheet or a polyethylene sheet and an adhesive tape. The flexible synthetic resin sheet is first fitted around the head and the adhesive tape is tied around the so fitted flexible film. The adhesive tape is then applied all over the film to profile the head. This profiled film is used as a female mold to prepare a male mold. A rubber coating or a synthetic resin coating is formed on the male mold and the coating is removed from the mold to obtain a wig base. This method, however, involves such a disadvantage that an accurate wig base can hardly be obtained due to rough formation of the female mold and shrinkage of the materials, i.e., the flexible synthetic resin sheets and the adhesive tape.

It is therefore an object of the present invention to provide a female mold for forming a head model which is capable of providing a wig base snugly fitted to a head of a wig wearer.

It is another object of the present invention to provide a female mold for forming a head model which is usable as a workbench for carrying out hair grafting and setting of a wig thereon.

In accordance with the present invention, there is provided a method for preparing a female mold for forming a head model, which comprises:

heating a thermoplastic resin sheet softenable and moldable at a relatively low temperature and hardenable at a room temperature;

pressing said sheet against a head; and

cooling said sheet to be hardened.

FIG. 1 is a perspective view of a clamping frame holding a material of a female mold;

FIG. 2 is a perspective view of the female mold;

FIG. 3 is an elevational view of a male mold;

FIG. 4 is a perspective view of a wig base;

FIG. 5 is a sectional view of a workable resin layer formed inside the female mold;

FIG. 6 is a perspective view of a male mold, i.e., a head model, released from the female mold;

FIG. 7 is a partly sectional elevational view of a workbench for a wig on which the male mold is mounted; and

FIG. 8 is a similar partly sectional elevational view of another form of a workbench for a wig.

Referring now to FIGS. 1 to 4, there is illustrated one embodiment of the present invention which is applied to the manufacturing of a wig base 12. A thermoplastic resin sheet which is softenable and moldable at a relatively low temperature, e.g., at a temperature of 40.degree. to 45.degree. C. where a human body does not get burnt, and hardenable at a room temperature is heated to a temperature higher than the softening point to soften the sheet. The so softened sheet is pressed against the head of a person who will wear a wig to be prepared so as to be swaged and then cooled to harden the sheet for preparing a female mold. A plaster is filled into the female mold to obtain a male mold, i.e., a model of the head. A flexible synthetic resin material is coated on the male mold and dried to obtain a wig base. As a specific example of the thermoplastic resin sheet softenable and moldable at a relatively low temperature and hardenable at a room temperature which is employable in the present invention, there can be mentioned a sheet of a trans-polyisoprene having a thickness of 2 to 3 mm. Natural materials such as balata and guttapercha may also be employed. As the plaster employable for preparing the male mold, there can be mentioned a plaster having a high hardness, high strength and high dimensional accuracy such as a dental plaster. In preparing the wig base by coating the flexible synthetic resin on the plaster male mold, it is preferred that a lubricant be preliminarily coated on the mold. As the lubricant, there may be employed silicone and fluorine plastic.

A sheet 1 of Kuraray TP-301 (trade name of trans-1,4-polyisoprene manufactured and sold by Kabushiki Kaisha Kuraray, in Japan; tensile strength (kg/cm.sup.2): 290; elongation (%): 450; hardness (Shore C): 78; melting point(.degree.C.): 67; density(g/cm.sup.3): 0.96) having a thickness of 2 mm, a length of 33 cm and a width of 33 cm is held by a clamping frame 4 comprised of two wooden frame members 2a and 2b openably connected by hinges 3a and 3b as illustrated in FIG. 1. The sheet is held at a height of about 3.5 cm from an electric heater of 445 W at 100 V or 300 W at 120 V and heated by the heater for about three minutes. Then, the semitranslucent sheet is turned transparent and softened. After the sheet is left to cool to a temperature not felt too hot to touch the sheet by a hand, the sheet is pressed against the head of a person who will wear a wig to be prepared, by holding the clamping frame 4 by hands for about seven minutes, until the sheet is cooled to turn semitranslucent again. Then, the sheet is removed from the head to obtain a female mold A as illustrated in FIG. 2. A marking line 5 is drawn in ink to indicate a portion desired for a wig base.

SSS GYPSTONE RC (trade name of a plaster manufactured and sold by SANESU GYPSUN CO. LTD., Japan) is gradually and dispersedly mixed with water in a basin in the ratio of 100 (g):25 (cc) and stirred for about three minutes. Thus, 1 kg to 2 kg of the mixture is prepared. A small part about (1/3) of the thus obtained paste is coated thinly on the inside of the female mold A and the rest is gently poured into the mold. At this time, one end of a stick 6 is placed at a central portion of the poured paste in the female mold A. The plaster is removed from the female mold A after it has passed 15 minutes, i.e., just before it reaches to an exothermic maximum temperature and left for about one hour to complete aggregation, then dried at 40.degree. C. by a drier for 30 minutes and then left half a day to obtain a plaster male mold B. A spherical portion 9 formed at another end of the stick 7 is fitted into a semi-spherical concavity 8 formed at an upper end of a stand 7, and a cap 10 is put thereon to tiltably support the male mold B. The stand 7 has suction pads 11 at a bottom face of the stand 7 so as to fix the stand on a work table.

BU 13 (trade name of a fluorine plastic of low temperature baking type manufactured and sold by PAMPUS) is sprayed onto the plaster mold from a distance of 20 to 35cm from the mold, dried at a temperature of 60.degree. C. to 70.degree. C. and heated at a temperature of 150.degree. C. for one hour. Polyurethane resin pellets are dissolved by DMF, coated thinly on the plaster mold and dried at a temperature of 60.degree. C. to 70.degree. C. This is repeated three times. The coating is then subjected to a heat treatment at a temperature of 120.degree. C. for ten minutes, left for three to four days to harden it completely and removed from the mold to obtain the wig base.

The thus obtained wig base is well fitted to the head of the person who will wear the wig.

FIGS. 5 to 8 illustrate the embodiment of the present invention which is applied to the manufacturing of a workbench for a wig. A fluid workable resin is spread on the inner surface of the female mold for the wig base and removed from the mold to obtain a hollow member. This hollow member is employable as a male mold or a head model on which the wig base is placed for being subjected to processing such as a hair grafting, setting, etc.

A lubricant such as a fluorine plastic is coated on the inside of a female mold as obtained in the manufacturing of the wig base as mentioned above. 100 parts by weight of a fluid workable resin such as a phenolic foam containing an epoxy resin and a phenol balloon which can receive a driven pin after formed is mixed with 25 parts by weight of a hardening agent such as a modified aliphatic polyamine for 2 to 3 minutes. 100 to 150g of the thus obtained mixture is poured into the female mold with the lubricant coated thereon and spread to a marker 13 for example by a spatula to form a layer 14 of the workable resin in a thickness of about 5mm and left for 8 to 10 hours to be hardened. The hardened resin is then released to obtain a hollow male mold B'.

Subsequently, an expanded polyurethane 15 is filled into the hollow of the male mold B'. After the polyurethane 15 is hardened, a stick 17 having a spherical portion 16 at a lower end thereof is embedded into the polyurethane 15. The spherical portion 16 is fitted into a semi-spherical concavity 19 formed at an upper end of a stand 18 and a cap 20 is fitted to the stand 18. Thus, a workbench is prepared. Numeral 21 designates suction pads formed on a bottom face of the stand 18.

The thus formed workbench is used in such a manner that the stand 18 is fixed on a table by the suction pads 21, a wig base is placed on the male mold B' to make hair grafting, the wig base is then placed on the mold B' inside out to effect coating on the inside of the wig base, and the wig base is then turned over again on the mold B' to finish setting of the wig. In this connection, it is to be noted that since the wig base is formed by using the same female mold profiled to the head of the wig wearer, the inside configuration of the wig base is in conformity with the outer contour of the workbench and is well fitted thereto. Thus, the above-mentioned operation can be carried out easily and accurately. Furthermore, since the material of the male mold B' provides a fine porous structure to allow driving of a pin, the wig base can be fixed to the workbench more positively.

FIG. 8 illustrates another form of a workbench wherein a wooden mold 22 is employed in place of the expanded polyurethane. In this case, a gap 23 is formed between the inner face of the mold B' and the outer face of the wooden mold to easily receive a pin driven thereinto.

## Claims

1. In a method for producing a wig base fitted to the head of the person who is to wear a wig produced from said base, the steps comprising: point of about 67.degree. C. and a thickness of about 2 mm in a perimetral clamping frame while heating the sheet until it softens and turns transparent; human hand; the wig sufficient to cause said head to bulge the central portion of said sheet to the shape of the top of said head and maintaining said bulge by holding the clamping frame by hand until the sheet is cooled sufficient to turn semitranslucent again; indicate the portion thereof desired for a wig base; inside of said bulge and then pouring the rest into the bulge; bulge; maximum temperature and leaving the plaster a time to complete aggregation and drying said plaster to obain a plaster male mold; support the male mold on a work table or the like; male mold and drying and heating same; polyurethane resin pellets dissolved by DMF and drying same; period of time to harden it completely and thereafter removing same from the male mold to obtain the wig base.

2. The method of claim 1 in which said trans-1,4-polyisoprene sheet is of tensile strength of about 290 kg/cm.sup.2, elongation about 450%, Shore C hardness about 78, density about 0.96 g/cm.sup.3, having a length and width about 33 cm.

3. The method of claim 1 in which said trans-1,4-polyisoprene sheet is of tensile strength of about 290 kg/cm.sup.2, elongation about 450%, Shore C hardness about 78, density about 0.96 g/cm.sup.3, having a length and width about 33 cm; members openably connected by hinges and defining said clamping frame; 3.5 cm from an electric heater of about 300 W to 445 W for about three minutes; said bulge for about seven minutes; aggregation, said drying including drying at about 40.degree. C. by a drier for about 30 minutes and then leaving the plaster about half a day to obtain said plaster male mold; other end of the stick into a semi-spherical concavity formed at an upper end of said stand, and putting a cap thereon; 60.degree. C. to 70.degree. C. and then heating at a temperature of about 150.degree. C. for about one hour; 60.degree. C. to 70.degree. C., and being repeated three times; ten minutes, said period of time being three to four days for hardening.