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

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 panel. A curved edge of the moldable panel is then formed by a mold. After that, the moldable panel and at least one second panel are connected to form a crown, to which a peak is subsequently connected to form the cap. Once the curved edge of the moldable panel is formed by heating and pressure application through the mold, the integrally formed moldable layer keeps the moldable panel in shape, so there is no need to support the outer layer of fabric and curve, for example, the front panel with two pieces of buckram that are stitched together, as is conventionally required.

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 panel. A curved edge of the moldable panel is then formed by a mold. After that, the moldable panel and at least one second panel are connected to form a crown, to which a peak is subsequently connected to form the cap. Once the curved edge of the moldable panel is formed by heating and pressure application through the mold, the integrally formed moldable layer keeps the moldable panel in shape, so there is no need to support the outer layer of fabric and curve, for example, the front panel with two pieces of buckram that are stitched together, as is conventionally required.

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.

Various fabric products incorporating exterior hydrostatic barriers and processes for manufacturing such fabric products are provided.

Woven hats and methods for manufacturing woven hats by using an ultrasonic sewing technology without a sewing thread are disclosed. One illustrative method comprises steps such as: cutting a raw material of a hat crown into a plurality of pieces, then bonding such material in pairs using an ultrasonic sewing machine, applying to seam areas a hot-pressing bonding technology of heat-seal adhesive tape, and/or otherwise completing the manufacturing of the hat crown; manufacturing a visor by using a high-frequency hot-pressing technology; manufacturing a sweatband by using a one-time hot-pressing technology; bonding the hat crown, the visor, and the sweatband with an ultrasonic sewing machine; and fixing a rear fastener or a tail belt through rivets. The disclosed technology makes it easier to realize intelligent and automatic reformation of the manufacturing line.

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.

Proposed is lower rollers of a hot air welder, and more particularly, to a lower roller structure of a hot air welder, which includes a first lower roller unit installed on a worktable to be pivoted vertically and a second lower roller unit installed on a main body to be slidably moved in front and rear, such that a welding operation of flat fabric and a welding operation of a cylindrical shape can be performed in a single hot air welder through alternate use of the first and second lower roller units.

Disclosed are a visor and a method of making the same. The method includes 1) preparing molds and molding material, 2) performing a primary injection molding, and 3) performing a secondary injection molding. According to the method, the first part and the second part are independently made on an injection mold, therefore the hardness of the first part and the second part can be made to be different so that the visor body consisting of the first part and the second part has different hardness at different positions. The disclosure further includes a visor, comprising a visor body which is composed of a first part and a second part, where the hardness of the first part is less than that of the second part.