Patent Publication Number: US-10765162-B2

Title: Cap and method of manufacturing a cap

Description:
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS 
     This application for patent is a continuation of U.S. application Ser. No. 16/316,400, filed Jan. 9, 2019, which is a 371 of International Application No. PCT/CN2016/089914, filed Jul. 13, 2016, of which all of the applications are incorporated by reference herein in their entirety 
    
    
     FIELD 
     The present disclosure is related to a method of assembling or manufacturing headwear such as a cap, and more particularly, to a cap assembly that incorporates a single-panel crown formed of stretchable fabric. 
     BACKGROUND 
     Headwear can include various components, such as a crown and a visor (e.g., bill). One type of headwear is a hat, such as a cap or a baseball cap, in which the crown is traditionally formed of six (6) crown panels or 5/4/3/2 crown panels because the fabric is flat, unless the crown is specially hand-crocheted with yarn. However, the multiple crown panels are connected together using conventional attachment techniques, such as stitching or sewing. Such conventional manufacturing techniques increase the time, complexity and cost of assembling or manufacturing components of a cap together. These types of conventional caps also are restrictive in terms of head size ranges, and thus, must be made in many different sizes to accommodate different wearers. Furthermore, the materials used for the flat crown panels in these caps are susceptible to wrinkling, particularly those which use heavier fabrics. 
     SUMMARY 
     A cap and method of assembling thereof is provided, which employ a single-panel crown formed of a stretchable fabric. The method of assembling a cap, such as for example a baseball cap, involves forming a single-panel crown for a cap from a single sheet or single piece of stretchable fabric, attaching a support layer to an interior, front portion of the single-panel crown with an adhesive, and attaching a visor and an elastic band to the single-panel crown with the attached support layer. The single-panel crown can be formed by heating and stretching the single sheet or single piece of stretchable fabric to form a hemispherical shape on a portion of the stretchable fabric, and cutting any extra edge portion or portions of the stretchable fabric that extend from or beyond the hemispherical shaped portion in order to form the single-panel crown for the cap. Heat can be applied to one or both sides of the stretchable fabric, and as heat is applied, a pressing force can be applied to the stretchable fabric using a hemispherical shaped fabric mold to stretch the portion of the stretchable fabric into the hemispherical shape. The stretchable fabric can be made of a woven or non-woven material, and can be an elastic fabric (or fabric with elastic properties) that includes 2% to 5% spandex, preferably around 3% of spandex. 
     The support layer can be made of buckram. To attach the support layer to the single-panel crown, a coat of an adhesive can be applied to a surface of the buckram or an interior, front portion of the single-panel crown. The buckram can then be pressed (e.g., heat pressed) against the interior, front portion of the single-panel crown so that the adhesive bonds the buckram to the interior, front portion of the single-panel crown. Furthermore, bonding tape can be applied over one or more seams that are formed between an edge of the buckram and an interior surface of the single-panel crown. Each of the one or more seams extends radially from an interior, central portion to a bottom edge of the single-panel crown, and the bonding tape covers the one or more seams and further connects the buckram to the single-panel crown. 
     The cap with a single-panel crown is designed to provide numerous benefits over conventional caps. For example, the single-panel crown can be formed from a stretchable fabric in a manner that requires substantially less labor in comparison to conventional crowns such as those formed by connecting multiple flat crown panels or by hand crocheting yarn. Thus, with a single-panel crown design as described herein, it is possible to assemble or manufacture a cap (e.g., a baseball cap) in a more efficient, faster and less costly manner in comparison to conventional caps. Furthermore, a cap with such a single-panel crown is able to cover a larger range of head sizes, has increased or improved tear strength by eliminating the need for stitching ordinarily employed to connect multiple flat crown panels together in conventional caps, and is less susceptible to wrinkling particularly when employing light or lighter stretchable fabric for the crown. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The description of the various exemplary embodiments is explained in conjunction with the appended drawings, in which: 
         FIG. 1  is a perspective view of an example headwear, such as an example cap that incorporates a single-panel crown formed from a single sheet or single piece of stretchable fabric, in accordance with an exemplary embodiment of the present disclosure. 
         FIG. 2  is a bottom view showing an interior or inside of the single-panel crown of the cap in  FIG. 1 . 
         FIGS. 3 through 8  illustrate various operations involved in an exemplary process of assembling or manufacturing a cap such as in  FIG. 1 . 
         FIG. 9  is a flow diagram of an exemplary process of assembling or manufacturing headwear, such as the cap in  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION OF THE EXAMPLE EMBODIMENTS 
       FIGS. 1 and 2  illustrate a headwear, such as a cap  100 . As shown in  FIG. 1 , the cap  100  includes a single-panel crown  110 . A top button  112  and a visor  120  are attached (or connected) to the crown  110 . The single-panel crown  110  has a hemispherical shape (e.g., a dome shape) and is formed of a stretchable fabric, preferably a light or lighter stretchable fabric. The fabric can be a woven or non-woven material, and can be an elastic fabric that is formed, such as for example with spandex (e.g., between 2% and 5% spandex, preferably around 3% spandex). As will be described in greater detail below, the single-panel crown  110  can be formed by heating and stretching a single sheet or single piece of a stretchable fabric into a hemispherical shape using a heat pressing system or heat press transfer machine with a suitable fabric-shaping mold or fabric mold (e.g., a hemispherical-shaped fabric mold). 
     As further shown in  FIG. 2 , the cap  100  also includes a support layer  230 , and an elastic band  260 . The support layer  230  is attached to an interior or inside of the single-panel crown  110  to provide structural support for a desired portion(s) of the single-panel crown  110  of the cap  100 . In this example, the support layer  230  is attached to an interior, front portion of the single-panel crown  110 . 
     The support layer  230  can be formed as a single panel or by connecting multiple support panels. For example, as shown in  FIG. 2 , the support layer  230  includes two support panels  230 A and  230 B, which can be connected together along their seam such as, for example, by sewing or stitching, with bonding tape, with an adhesive, or a combination thereof In this example, the two support panels  230 A and  230 B together with a strip  240  of bonding tape or fabric are stitched and the strip  240  covers the seam between the support panels  230 A and  230 B. The support layer  230  can be formed of a rigid material, such as buckram. 
     The support layer  230  can be attached to the interior or inside of the single-panel crown  110  through heat transfer techniques using an adhesive (e.g., a fabric adhesive), as well as using bonding tape. As shown in  FIG. 2 , two strips  250 A and  250 B of bonding tape are applied along respective seams between an outer edge or periphery of the support layer  230  and the interior of the single-panel crown  110 . The strips  250 A and  250 B of bonding tape further attach the support layer  230  to the single-panel crown  110 , and cover respective seams therebetween that extend radially from a central or center portion to a bottom edge (or rim)  114  of the single-panel crown  110 . The bonding tape, as used herein, can be a single-sided or double-sided heat bonding tape or adhesive tape (e.g., a pressure sensitive adhesive tape). An adhesive, as used herein, can be a fabric adhesive that is applied with or without heat to bond two or more components together. 
     The elastic band  260  is attached around an interior of the bottom edge  114  of the single-panel crown  110  with the attached support layer  230 . The elastic band  260  can be a sweatband. The visor  120  and the elastic band  260  can be attached to the single-panel crown  110  by sewing or stitching them to the single-panel crown  110  (see e.g., stitches or stitching  116  in  FIG. 1 ). 
       FIGS. 3 through 8  illustrate an exemplary step-by-step process of assembling or manufacturing a cap with a single-panel crown, such as shown in  FIG. 1 . As shown in  FIGS. 3 and 4 , a single sheet or single piece of stretchable fabric  310  is provided. The stretchable fabric  310  can be an elastic fabric. A portion of the stretchable fabric  310  is heated and pressed with a sufficient force by a hemispherical-shaped fabric mold  10  (of a heat press transfer machine or heat pressing system) to form a hemispherical shape on the fabric  310 , i.e., a hemispherical-shaped portion  410 . The amount of force, temperature and time used in the heating and stretching processes can vary according to the properties of the stretchable fabric  310  in the heating and stretching operations. The size and shape of the mold  10  can be changed, as desired, to accommodate different types of caps and head sizes or head size ranges. 
     As shown in  FIGS. 5 , the stretchable fabric  310  is subsequently cut or trimmed, if necessary, to remove any extra edge portion or portions  510  that extend beyond the hemispherical-shaped portion  410 . In this way, a single-panel crown  110  is formed from the hemispherical-shaped portion  410  of the stretchable fabric  310 . As an alternative, the stretchable fabric  310  can be cut beforehand or pre-cut into a fabric blank (e.g., a circular or oval blank of the stretchable fabric  310 ) with a suitable size and shape to avoid the necessity of performing a trimming or cutting operation after the heating and stretching processes. For example, the fabric blank can be heated and stretched, as described herein, to form the single-panel crown  110  with a hemispherical shape. 
     As shown in  FIG. 6 , a support layer  230  is to be attached to an interior or inside of the single-panel crown  110 , which is noted by reference  600 . In this example, the support layer  230  is formed of two support panels  230 A and  230 B (e.g. triangular-shaped panels), which are connected by sewing or stitching along a seam formed by adjacent outer edges of the support panels  230 A and  230 B. For example, a strip  240  of fabric or bonding tape, which is applied over the seam between the support panels  230 A and  230 B, is sewed or stitched to attach or to further attach the support panels  230 A and  230 B along with the strip  240  together. However, the support panels  230 A and  230 B can be attached in other ways, such as using adhesives (e.g. fabric adhesives), bond taping, etc. 
     As shown by reference  700  in  FIG. 7 , the support layer  230  can be attached to the interior or inside of the single-panel crown  110  using an adhesive  630  (e.g., fabric adhesive). For example, a coating of the adhesive  630  is applied on one side or surface of the support layer  230 . The support layer  230  is thereafter inserted into the single-panel crown  110 , and then pressed against an interior, front portion of the single-panel crown  110  to attach the support layer  230  to the single-panel crown  110 . As shown in  FIG. 8 , two strips  250 A and  250 B of bonding tape are applied along respective seams between an outer edge or periphery of the support layer  230  and the interior of the single-panel crown  110  (also referred to as “seamless taping”). The strips  250 A and  250 B of bonding tape further attach the support layer  230  to the single-panel crown  110 , and cover respective seams therebetween that extend radially from a central or center portion to a bottom edge (or rim)  114  of the single-panel crown  110 . The top button  112  is also attached to a central portion or center of the single-panel crown  110  with a metal snap or the like. 
     As further shown in  FIG. 8 , a visor  120 , an elastic band  260  are attached to the single-panel crown  110  with the support layer  230 . For example, the elastic band  260  is attached around an interior of the bottom edge  114  of the single-panel crown  110  with the attached support layer  230 . The visor  120  and the elastic band  260  can be attached to the single-panel crown  110  by sewing or stitching them together to the single-panel crown  110  (see e.g., stitches or stitching  116  in  FIG. 1 ) or separately to the single-panel crown  110 . 
       FIG. 9  is a flow diagram of an exemplary process  900  by which a headwear, such as for example a cap as shown in  FIG. 1 , is assembled and manufactured with a single-panel crown. The process  900  can begin with the provision of a single sheet or single piece of stretchable fabric, at reference  902 . The stretchable fabric can be made of woven or non-woven material, and can preferably be a light or lighter stretchable fabric. As previously discussed, the stretchable fabric can be an elastic fabric that incorporates spandex, such as for example between 2% to 5% of spandex or preferably around 3% of spandex. 
     At reference  904 , the stretchable fabric is heated and stretched so at least a portion thereof forms a hemispherical shape (e.g., a dome or half-sphere shape). A hemispherical-shaped fabric mold or other suitable fabric mold of a heat press transfer machine or heat pressing system can be used to heat press, and thus, stretch the stretchable fabric into a desired shape (or dimensions). The stretchable fabric can be heated on one or both sides when stretching the fabric. 
     At reference  906 , any extra edge portion or portions of the stretchable fabric that extend from or beyond the hemispherical-shaped portion is cut or trimmed off in order to form a single-panel crown for a cap. 
     At reference  908 , a support layer is attached to an inside or interior surface of the single-panel crown. For baseball or similar caps, the support layer can be attached to an interior, front portion of the single-panel crown. As previously discussed, the support layer can be made of buckram, and can be formed of one or more support panels which are attached together such as by sewing or stitching, adhesive (e.g., fabric adhesive), bonding tape or a combination thereof, or by other conventional attachment techniques. For example, the support layer can initially be attached to the single-panel crown with an adhesive, and then bonding tape can be applied over the seams between outer edge or periphery of the support layer and the interior of the single-panel crown. 
     At reference  910 , the visor and the elastic band (e.g., a sweatband) is attached to the single-panel crown, such as by sewing or stitching. The visor and the elastic band can be attached separately to the single-panel crown or attached together (e.g., at the same time or simultaneously) to the single-panel crown. 
     At reference  912 , other cap manufacturing processes may be performed to customize the cap. For example, these and other conventional cap manufacturing processes may include embroidering a logo(s) or printing a logo(s), e.g., a print logo, on the cap. 
     The headwear and method of assembling thereof, which are shown and described above with reference to the figures, are simply provided as examples. It should be understood that the headwear can include a single-panel crown having a different or varying size, shape and configuration. Although the headwear in  FIGS. 1 and 2  is shown as a particular type of a cap, such as a baseball cap, the single-panel crown manufacturing technique can be used to assemble or manufacture other types of caps with a visor (e.g., a bill) and having a different or varying dimensions (e.g., size and shape). In general, headwear components (including those described herein), layers of materials or accessories (e.g., lining, liners or backing for the single-panel crown, etc.) can also be attached or connected using various attachment techniques, such as sewing or stitching, adhesive (e.g., fabric adhesive), bonding tape, or a combination thereof and/or other conventional techniques for attaching components of a headwear together. Furthermore, the assembling operations can be performed in a different order, and may omit some operations or add other operations to assemble a cap with a single-panel crown. 
     As discussed herein, a stretchable fabric can be heated and stretched into a desired shape with a heat press transfer machine or heat pressing system that employs fabric mold. The fabric mold can include a male mold part (e.g., mold  10  in  FIGS. 3 and 4 ) and a counterpart-female mold part, which when engaged stretches the stretchable fabric arranged therebetween into a desired shape according to the shape of the mold parts (e.g., hemispherical shape). Alternatively, the fabric mold may include only a male mold part, upon which the stretchable fabric is pressed against and stretched. 
     Words of degree, such as “about”, “substantially”, and the like are used herein in the sense of “at, or nearly at, when given the manufacturing, design, and material tolerances inherent in the stated circumstances” and are used to prevent the unscrupulous infringer from unfairly taking advantage of the invention disclosure where exact or absolute figures and operational or structural relationships are stated as an aid to understanding the invention. 
     While particular embodiments and applications of the present disclosure have been illustrated and described, it is to be understood that the present disclosure is not limited to the precise construction and compositions disclosed herein and that various modifications, changes, and variations can be apparent from the foregoing descriptions without departing from the invention.