A cap and a method for forming the same are provided. An integrally formed outer layer of fabric and an integrally formed moldable layer are adhesively bonded together to form a moldable front panel. A curved front side of the front panel is then formed by a mold. After that, the front panel and a plurality of side panels are connected to form a crown, and a peak is subsequently connected to the front panel of the crown to form the cap. Once the curved front side of the front panel is formed by heating and pressure application through the mold, the integrally formed moldable layer keeps the front panel in shape, so there is no need to support the outer layer of fabric and curve the front panel with two pieces of buckram that are stitched together, as is conventionally required.

Disclosed are a hat and a manufacturing method therefor and a hat top shaping device, the hat comprising: a seamless hat top without seams, wherein same is integrally formed by hot stretching a piece of a flat knitted fabric blank containing a vitrifiable petroleum chemical fibre material; and a bongrace jointed to the seamless hat top. The hat top of the hat can save on the production time and cost. The hat top of the hat can be made into various hat types and a variety of raw materials can be selected for same. The hat top of the hat is a hat top without seams, completely fitting the user's headform, and can be made by selecting a breathable material, thereby improving the aesthetics and comfort when wearing same.

Disclosed are a hat and a manufacturing method therefor and a hat top shaping device, the hat comprising: a seamless hat top without seams, wherein same is integrally formed by hot stretching a piece of a flat knitted fabric blank containing a vitrifiable petroleum chemical fibre material; and a bongrace jointed to the seamless hat top. The hat top of the hat can save on the production time and cost. The hat top of the hat can be made into various hat types and a variety of raw materials can be selected for same. The hat top of the hat is a hat top without seams, completely fitting the user's headform, and can be made by selecting a breathable material, thereby improving the aesthetics and comfort when wearing same.

A brim extender attaches to any standard baseball-style cap and may provide one or more functions, such as (1) extending sun protection along the sides and posterior portion of the hat, (2) changing the style and appearance of the hat, (3) providing a new promotional item (e.g., a new thing that can be labeled, colored, or styled to market a brand), and/or (4) providing an added barrier between the head and the crown of the cap to shield or partially shield the cap from perspiration and other substances coming from the scalp or hair.

A brim extender attaches to any standard baseball-style cap and may provide one or more functions, such as (1) extending sun protection along the sides and posterior portion of the hat, (2) changing the style and appearance of the hat, (3) providing a new promotional item (e.g., a new thing that can be labeled, colored, or styled to market a brand), and/or (4) providing an added barrier between the head and the crown of the cap to shield or partially shield the cap from perspiration and other substances coming from the scalp or hair.

A baseball cap and method of assembling thereof is provided. The cap includes a single-panel crown that is formed from a single sheet or single piece of stretchable fabric, such as using heat pressing techniques. The single-panel crown has a hemispherical shape. The cap further includes a support layer, such as made from buckram, which is attached to an interior, front portion of the single-panel crown, and a visor and an elastic band which are attached to the single-panel crown.

A baseball cap and method of assembling thereof is provided. The cap includes a single-panel crown that is formed from a single sheet or single piece of stretchable fabric, such as using heat pressing techniques. The single-panel crown has a hemispherical shape. The cap further includes a support layer, such as made from buckram, which is attached to an interior, front portion of the single-panel crown, and a visor and an elastic band which are attached to the single-panel crown.

A manufacturing method including providing a mold including at least two mold parts having first and second molding surfaces which are complementarily profiled to give shape to headwear; shaping a first substrate in the mold resulting in the first substrate having a non-planar profile which matches at least a portion of the profile of the molding surfaces; shaping a second substrate in the mold resulting in the second substrate having a non-planar profile which matches the profile of the molding surfaces; overlaying the first substrate on the second substrate and matching their non-planar profile to form a combined substrate; placing a third substrate in the mold with the combined substrate, sandwiching the first substrate; and shaping the third substrate with the combined substrate in the mold resulting in the third substrate having a non-planar profile which matches the profile of the molding surfaces, thereby forming a seamless structure for the headwear.

A manufacturing method including providing a mold including at least two mold parts having first and second molding surfaces which are complementarily profiled to give shape to headwear; shaping a first substrate in the mold resulting in the first substrate having a non-planar profile which matches at least a portion of the profile of the molding surfaces; shaping a second substrate in the mold resulting in the second substrate having a non-planar profile which matches the profile of the molding surfaces; overlaying the first substrate on the second substrate and matching their non-planar profile to form a combined substrate; placing a third substrate in the mold with the combined substrate, sandwiching the first substrate; and shaping the third substrate with the combined substrate in the mold resulting in the third substrate having a non-planar profile which matches the profile of the molding surfaces, thereby forming a seamless structure for the headwear.

A system for creating a covered hat using an upper form having a top surface, a bottom edge, and side walls having an elongated cylindrical shape between the top surface and bottom edge. A stand having an upper block is inserted into the upper form against the top surface. A rigid ring insert is placed within the form and aligned with the bottom edge. A covering sheet made of a textile material having outer edges is centered over the top surface of the upper form. A rope band secures the covering sheet tightly against the upper form and is aligned with the ring insert. The outer edges are pulled downwardly to remove wrinkles, the covering sheet is stitched in place to the upper form, and the upper form is severed just above the ring for subsequent attachment to a hat lower part.