Hat

Abstract

Provided is a hat formed from a single piece of fabric. The single piece of fabric comprises parallel regions of fabric including first and second headband regions and at least one intermediate region. The headband regions are joined at their ends to form a headband and the intermediate region forms the crown of the hat. The headband regions and the at least one intermediate region are of differing stiffness and/or thickness.

Claims

1. A hat formed from a single piece of fabric, the single piece of fabric comprising: parallel regions of fabric including first and second headband regions; and at least one intermediate region, the first and second headband regions being joined at their ends to form a headband and the intermediate region forming a crown of the hat, wherein the first and second headband regions and the at least one intermediate region have at least one of differing densities of threads, different patterns of threads, and yarns of differing weights.

2. The hat according to claim 1, wherein the first and second headband regions are of greater stiffness, greater thickness, or both greater stiffness and thickness than the at least one intermediate region.

3. The hat according to claim 1, wherein a stiffening agent or a setting agent is applied to at least selected regions of the fabric.

4. The hat according to claim 1, wherein the first and second headband regions have widths of between 3 cm and 40 cm and the at least one intermediate region has a width of between 5 cm and 40 cm.

5. The hat according to claim 1, wherein the single piece of fabric comprises two headband regions and one intermediate region.

6. A hat formed from a single piece of fabric, the single piece of fabric comprising: parallel regions of fabric including first and second headband regions; and at least one intermediate region, the first and second headband regions being joined at their ends to form a headband and the intermediate region forming a crown of the hat, wherein the first and second headband regions are formed using yarns of heavier gauge or stiffness than the intermediate regions.

7. The hat according to claim 1, wherein the first and second headband regions are joined at the ends by stitching or by ultrasonic welding.

8. The hat according to claim 1, wherein the fabric from which the hat is made comprises one or more of stiffening elements, an elastic element and a metal component.

9. The hat according to claim 1, wherein the fabric from which the hat is made comprises one or more substances selected from the group of: scents, odour-absorbing agents, anti-crease agents, waterproofing agents, softening agents, optical brighteners, fire retardant or flame-proofing agents, and final finishing chemicals.

10. The hat according to claim 1, which is in the shape of a garrison cap or a chef's toque.

11. A method of manufacturing a hat comprising: a) providing a single piece of fabric, the single piece of fabric comprising parallel regions of fabric including first and second headband regions and at least one intermediate region, wherein the first and second headband regions and the at least one intermediate region have at least one of differing densities of threads, different patterns of threads, and yarns of differing weights; b) folding the piece of fabric such that the first and second headband regions are brought together and edges of the fabric are aligned; and c) joining the first and second headband regions to form a headband severing the fabric at the points at which the headband regions are joined, to form discrete hats.

12. The method according to claim 11 further comprising forming the fabric into a desired shape prior to joining of the first and second headband regions.

13. The method according to claim 11, wherein the fabric is used in a continuous strip.

14. The method according to claim 13, wherein the first and second headband regions are joined together at intervals along a length of the continuous strip, the intervals corresponding to a size of the finished hat.

15. The method according to claim 11, wherein, when the first and second headband regions are brought together, the intermediate region lies between the first and second headband regions so that ends are captivated between the first and second headband regions when the first and second headband regions are joined together.

16. The method according to claim 11, wherein, when the first and second headband regions are brought together, the intermediate region is folded outside the first and second headband regions to form an inverted V shape over the first and second headband regions when the first and second headband regions are joined together.

17. The method according to claim 11, wherein the first and second headband regions are joined by stitching or by ultrasonic welding.

18. The method according to claim 11, wherein the single piece of fabric incorporates at least one of stiffening elements, elastic elements and metal components.

19. The method according to claim 11, wherein the single piece of fabric incorporates one or more antimicrobial agents.

20. The method according to claim 11, further comprising applying printed material to the hat.

21. A plurality of connected hats, each hat being formed from a single piece of fabric, the single piece of fabric comprising parallel regions of fabric including first and second headband regions and at least one intermediate region, the first and second headband regions being joined at ends to form a headband and the intermediate region forming a crown of the hat, wherein the first and second headband regions and the at least one intermediate region have at least one of differing densities of threads, different patterns of threads, and yarns of differing weights, the plurality of connected hats being joined together at junctions adjacent the ends of the first and second headband regions to form a string of connected hats, such that a terminal hat may be separated from the string by severing of the string at a junction between one hat and a next hat in the string.

22. The plurality of hats according to claim 21, wherein the first and second headband regions are joined using ultrasonic welding.

23. The plurality of hats according to claim 21, wherein the junction between two hats in the string is a line of weakness.

24. The plurality of hats according to claim 23, wherein the line of weakness is a line of perforations.

25. The plurality of hats according to claim 21, wherein the plurality of connected hats are supplied in a roll.

26. The plurality of hats according to claim 21, wherein the plurality of connected hats are supplied in a concertina arrangement.

Description

(1) The invention will now be described in greater detail, by way of example only, with reference to the accompanying drawings, in which

(2) FIG. 1 shows part of an elongate knitted fabric piece used in the manufacture of a hat according to the invention;

(3) FIGS. 2(a) and 2(b) show the manner in which the fabric piece of FIG. 1 is folded during manufacture of the hat;

(4) FIG. 3 is a perspective view of a hat produced in accordance with the invention;

(5) FIG. 4 shows part of a string of connected hats produced in accordance with the invention.

(6) FIGS. 5(a) and 5(b) show a schematic drawing of a chefs' toque produced according to the invention.

(7) FIGS. 6(a) and 6(b) show an alternative manner in which the fabric piece of FIG. 1 may be folded during manufacture of the hat.

(8) FIGS. 7(a) and 7(b) show a schematic drawing of an open-topped chefs' toque produced in accordance with the invention.

(9) FIGS. 8(a) and 8(b) show a schematic drawing of an alternative style of hat produced according to the invention.

(10) Referring first to FIG. 1, a hat suitable for use in commercial or other establishments in which workers are required to cover their hair is produced from a single piece of fabric 2. The fabric 2 is knitted as a continuous strip with an overall width of approximately 25 cm, and comprises three distinct longitudinally extending regions A1,A2,B of approximately equal width. The headband regions A1,A2 have a relatively dense knitted structure, whereas the intermediate region B has a considerably less dense and more open knitted structure.

(11) The fabric 2 is knitted in generally conventional manner using a Raschel knitting machine.

(12) In order to form the hat, the fabric 2 is passed over a suitably shaped former, so that it is folded in the manner depicted in FIGS. 2(a) and 2(b), ie the two headband regions A1,A2 are brought together with the intermediate region B folded between them and the outer edges of the fabric 2 lying adjacent to each other

(13) The two headband regions A1,A2 are then joined together along the broken lines indicated in FIGS. 2(a) and 2(b). In the illustrated embodiment, this is achieved by two lines of stitching, but alternative means such as ultrasonic welding may also be used.

(14) Finally, individual hats may be separated from the fabric 2 by cutting. To facilitate this, the fabric 2 is cut between the double lines of stitching. Where the headband regions are joined together by welding, the welded join may be made sufficiently wide that a cut may be made along its centre.

(15) The finished hat is shown in FIG. 3. The headband regions A1,A2 of the fabric are joined to form a headband that fits closely to a wearer's head. Being formed of a knitted fabric, the headband is able to stretch so as to fit differently sized heads. The intermediate region B of the fabric constitutes the crown of the hat. Being of lighter, more open structure, the crown portion allows breathability and flexibility, preventing the user from becoming too warm. The two headband regions have a denser structure, which makes them generally opaque and which confers on the hat a shape akin to that of a hat made by a more complex CMT process. The headband regions may be printed with branding or other promotional information.

(16) It will be appreciated that although in the illustrated embodiment the crown portion of the hat has a very open structure and the headband regions have a denser (though still somewhat open) structure, in other embodiments one or more of the respective regions of the fabric may be coated with a stiffening or setting agent or the like, the effect of which is to give those region(s) a solid or continuous surface.

(17) Elastic elements may optionally be incorporated into the fabric 2 along its outer edges O1, O2, such that in the finished hat the elastic elements are situated along the lower edge of the hat as illustrated in FIG. 3. This allows for one size of hat to fit all users snugly and comfortably. Such elastic elements may take various forms. For instance, they may be discrete elastic yarns that are incorporated into the knitted structure of the fabric, or the knitted ground structure may include such yarns or fibres.

(18) In an alternative process, rather than individual hats being cut off at the point of manufacture, the hats may be supplied in the form of a string of hats, individual hats being separated by lines of weakness such that individual hats may be separated from the string, eg by being torn off immediately prior to use. An example of such a string of hats is shown in FIG. 4.

(19) The string of hats shown in FIG. 4 is formed as described above with reference to FIGS. 1 to 3, but individual hats are not separated from the fabric at the point of manufacture. During production, the two outer portions A1, A2 are joined together at intervals using ultrasonic welding, resulting in the formation of welds W as shown in FIG. 4. The welds are approximately 1 cm in width and, in order to facilitate the subsequent separation of hats from the string, perforations are introduced down the centre of each weld W, as indicated by the broken lines in FIG. 4. This allows an individual hat to be easily torn from the end of the string.

(20) The string of hats may be formed into, for example, a roll that can be fitted into a suitable dispenser that can be installed at a workplace and from which individual hats may be drawn, eg by employees arriving at the workplace. Alternatively, the string of hats may be supplied folded in a concertina-like arrangement. This may be fitted into a suitable box or dispenser, from which individual hats can be drawn as required.

(21) The invention may be adapted to produce different styles of hats. For example, a schematic diagram of a chefs' toque produced according to the invention is shown in FIGS. 5(a) and 5(b). The fabric 3 used to produce the hat is knitted as a continuous band, and comprises the regions A1, A2 and B as described with reference to FIG. 1, and gathered regions C1,C2. Gathered regions C1,C2 have one or more lines of elastic incorporated into the fabric, as indicated by the broken lines in FIG. 5(a).

(22) In order to form the chefs' toque, the fabric 3 is passed over a suitably shaped former, so that it is folded in a manner analogous to that depicted in FIGS. 2(a) and 2(b), ie the two headband regions A1,A2 are brought together, and the two gathered regions C1,C2, are brought together with the intermediate region B folded between them and the outer edges of the fabric 3 lying adjacent to each other.

(23) The two headband regions A1,A2 and the two gathered regions C1,C2 are then joined together in a manner analogous to joining along the broken lines indicated in FIGS. 2(a) and 2(b). In the illustrated embodiment, this is achieved by two lines of stitching, but alternative means such as ultrasonic welding may also be used.

(24) Finally, individual hats may be separated from the fabric 3 by cutting. To facilitate this, the fabric 3 is cut between the double lines of stitching. Where the headband and gathered regions are joined together by welding, the welded join may be made sufficiently wide that a cut may be made along its centre. Alternatively, the welding operation may simultaneously cut the fabric.

(25) The gathered regions C1,C2 provide the chefs' toque with height, and the lines of elastic cause the hat to puff out in the conventional style as illustrated in FIG. 5(b). The height of the toque may be adjusted by altering the number of lines of elastic and/or the spacing between them. The intermediate region B forms the crown of the toque.

(26) Alternatively, a hat according to the invention may be formed by passing the fabric 2 over a suitably shaped former, so that it is folded in the manner depicted in FIGS. 6(a) and 6(b) ie the two headband regions A1,A2 are brought together with the intermediate region B folded such that it forms an inverted V shape over the headband region, with the outer edges of the fabric 2 lying adjacent to each other. The two headband regions A1,A2 are then joined together along the broken lines indicated in FIGS. 6(a) and 6(b). This method of folding may also be adapted for other styles of hat such as the chefs' toque.

(27) The hat according to the invention may also be an item of open-topped headwear, such as an open-topped chefs' toque, as illustrated in FIGS. 7(a) and 7(b). The fabric 4 used to produce the hat is knitted as a continuous stream, and comprises the headband region A1 as described with reference to FIG. 1, and gathered region C1 as described with reference to FIG. 5(a).

(28) To form the open-topped chefs' toque, the fabric 4 is cut to a length corresponding to the circumference required in the finished headwear, and folded so that the two ends of the headband region A1 are brought together and the two ends of the gathered region C1 are brought together, forming a loop. The two ends of the headband region A1 are joined together, and the two ends of the gathered region C1 are joined together. This may be achieved by any suitable means, including stitching or ultrasonic welding.

(29) The gathered region C1 provides the open-topped chefs' toque with height and causes it to puff out in the conventional style. The height of the toque may be adjusted by altering the number of lines of elastic and/or the spacing between them.

(30) A schematic drawing of an alternative style of hat that may be produced according to the invention is shown in FIG. 8(b). The fabric 5 used to produce the hat is knitted as a continuous band, and comprises headband regions A1 and A2 as described with reference to FIG. 1; flexible regions D1,D2; crown region E, and sweatband regions S1,S2 as shown in FIG. 8(a). Headband regions A1,A2 and crown region E have a higher density of knitted or woven threads than flexible regions D1, D2. Sweatband regions S1,S2 form part of headband regions A1,A2, and may be created by producing a thicker fabric, using a different yarn, eg a microfiber or wick away fibre, using a different knit construction which is designed to wick the moisture away from the user's forehead, or by using any combination of these methods. The width of the crown region E is larger than the desired diameter of the finished hat.

(31) At the junction between regions D1 and E, and between regions E and D2, there are fold lines L incorporated into the fabric 5. These may take the form of a line of weakness in the fabric, eg by the introduction of a line which is of lower density than the surrounding fabric, or a ridge in the fabric, eg by the introduction of a line which is of higher density than the surrounding fabric.

(32) To form the alternative style of hat, the fabric 5 is passed over a suitably shaped former, so that it is folded in a manner analogous to that depicted in FIGS. 6(a) and 6(b) ie the two headband regions A1,A2 are brought together with the flexible regions D1,D2 and the crown region E folded such that they form an inverted V shape over the headband region, with the outer edges of the fabric 5 lying adjacent to each other. The two headband regions A1,A2 are then joined together along the broken lines indicated in FIGS. 6(a) and 6(b). In the illustrated embodiment, this is achieved by two lines of stitching, but alternative means such as ultrasonic welding may also be used.

(33) Finally, individual hats may be separated from the fabric 5 by cutting. To facilitate this, the fabric 5 is cut between the double lines of stitching. Where the headband regions are joined together by welding, the welded join may be made sufficiently wide that a cut may be made along its centre.