CAP AND METHOD OF MANUFACTURING THE SAME

Abstract

A cap according to an embodiment of the present disclosure includes a crown part manufactured by connecting a plurality of crown panels, a visor part attached to a lower end of the crown part, and a sweatband part attached to an inner lower end of the crown part, in which two front panels, among the plurality of crown panels, each include a lining panel configured to define an inner side of the crown part, and an outer panel configured to define an outer side of the crown part and be cut out with an area larger than the lining panel, and in which at least two crown panels, which are adjacent to each other among the plurality of crown panels, are connected to each other by first sewing.

Claims

1. A cap comprising: a crown part manufactured by connecting a plurality of crown panels; a visor part attached to a lower end of the crown part; and a sweatband part attached to an inner lower end of the crown part, wherein two front panels, among the plurality of crown panels, each include a lining panel configured to define an inner surface of the crown part, and an outer panel configured to define an outer surface of the crown part and be cut out larger than the lining panel, and wherein at least two crown panels, which are adjacent to each other among the plurality of crown panels, are connected to each other by first sewing.

2. The cap of claim 1, wherein: the first sewing is performed in a state in which the crown panels, which are adjacent to each other among the plurality of crown panels, overlap each other.

3. The cap of claim 2, wherein: the first sewing couples the outer panels at a distance spaced apart from an edge of the crown panel.

4. The cap of claim 3, wherein: in a state in which the adjacent crown panels are deployed, ends of the coupled outer panel are leaned toward at least one side of the crown panel that is deployed, such that a seam portion is formed.

5. The cap of claim 4, wherein: in the state in which the adjacent crown panels are deployed, a seam cover tape is attached in a length direction of the crown panel to cover and surround the first sewing portion and the seam portion.

6. The cap of claim 5, wherein: the seam cover tape has a thickness of 0.1 mm to 1.0 mm.

7. The cap of claim 5, wherein: the seam cover tape has a width wider than a width of the seam portion.

8. The cap of claim 5, wherein: the seam cover tape is made of any one of synthetic fiber and natural fiber or a blend thereof.

9. The cap of claim 5, wherein: in the state in which the adjacent crown panels are deployed, the seam cover tape, the seam portion, the lining panel, and the outer panel are fixed by second sewing.

10. The cap of claim 1, wherein: the outer panel is made of any one of synthetic fiber and natural fiber or a blend thereof.

11. The cap of claim 1, wherein: the outer panel is made of polyester or nylon.

12. The cap of claim 1, wherein: the outer panel is made of any one of cotton, rayon, and wool or a blend thereof.

13. The cap of claim 1, wherein: a crown part panel corresponding to a front portion of the cap is configured as one crown panel which has a split portion at an upper half, and wherein the split portion at the upper half of the crown panel is connected by sewing in a state in which the one crown panel is folded.

14. The cap of claim 13, wherein: the crown panel is folded outwards so that the outer panel overlaps half and half.

15. The cap of claim 14, wherein: the sewing is performed to couple the split portion at the upper half of the outer panel at a distance spaced apart from an edge of the crown panel.

16. The cap of claim 15, wherein: in the state in which the crown panel is deployed, ends of the coupled portion of the outer panel are folded each toward opposite sides of the crown panel that is deployed, such that a seam portion is formed.

17. The cap of claim 15, wherein: in the state in which the crown panel is deployed, ends of the coupled portion of the outer panel are leaned toward one side of the crown panel that is deployed, such that a seam portion is formed.

18. A method of manufacturing a cap according to claim 1, the method comprising: cutting out a plurality of first panels configured to constitute an outer fabric; cutting out a plurality of second panels configured to constitute a lining; manufacturing a plurality of third panels, which constitute the crown part of the cap, by attaching the first and second panels; connecting at least two third panels, which are adjacent to each other among the plurality of third panels, by first sewing; placing a seam cover tape to cover a first sewing portion and a seam portion which is formed by deploying the connected third panels, and surrounding the seam portion; and performing second sewing on the seam cover tape and the third panels.

19. The method of claim 18, further comprising: attaching a sweatband part to an inner periphery of a lower end of the crown part; attaching a top button to an apex of an uppermost portion of the crown part; attaching a visor part to an outer portion of the lower end of the crown part; and adding embroidery on an outer surface of the third panels.

20. A method of manufacturing a cap according to claim 13, the method comprising: cutting out a first panel configured to constitute an outer fabric; cutting out a second panel configured to constitute a lining; manufacturing a third panel, which constitutes the crown part of the cap by attaching the first and second panels; connecting an upper split portion of the third panel by first sewing; placing a seam cover tape to cover a first sewing portion and a seam portion which is formed by deploying the connected upper split portion of the third panel, and surrounding the seam portion; and performing second sewing on the seam cover tape and the third panel.

21. The method of claim 20, further comprising: attaching a sweatband part to an inner periphery of a lower end of the crown part; attaching a top button to an apex of an uppermost portion of the crown part; attaching a visor part to an outer portion of the lower end of the crown part; and adding embroidery on an outer surface of the third panel.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0033] FIG. 1 is a view illustrating a cap product in the related art.

[0034] FIGS. 2A to 2E are views illustrating a process of manufacturing a crown of a cap manufactured by a traditional sewing method in the related art.

[0035] FIGS. 3A to 3F are views illustrating a process of manufacturing a crown of a cap according to an embodiment of the present disclosure.

[0036] FIGS. 4A to 4F are views illustrating a process of manufacturing a crown of a cap according to another embodiment of the present disclosure.

[0037] FIG. 5 is a flowchart that lays out a manufacturing process of a cap according to an embodiment of the present disclosure.

[0038] FIG. 6 is a flowchart that lays out a manufacturing process of a cap according to an embodiment of the present disclosure.

DETAILED DESCRIPTION OF THE EMBODIMENTS

[0039] Hereinafter, embodiments of the present disclosure will be described in detail with reference to the accompanying drawings so that those with ordinary skill in the art to which the present disclosure pertains may easily carry out the embodiments. The present disclosure may be implemented in various different ways and is not limited to the embodiments described herein.

[0040] In addition, the constituent elements having the same configurations in several embodiments will be assigned with the same reference numerals and described only in the representative embodiment, and only the constituent elements, which are different from the constituent elements according to the representative embodiment, will be described in other embodiments.

[0041] It is noted that the drawings are schematic and are not illustrated based on actual scales. Relative dimensions and proportions of parts illustrated in the drawings are exaggerated or reduced in size for the purpose of clarity and convenience in the drawings, and any dimension is just illustrative but not restrictive. The same reference numerals designate the same structures, elements or components illustrated in two or more drawings in order to exhibit similar characteristics. When one component is described as being positioned above or on another component, one component can be positioned directly on another component, and one component can also be positioned on another component with other components interposed therebetween.

[0042] An embodiment of the present disclosure illustrates a specific example of the present disclosure. As a result, various modifications of each drawing are expected. Therefore, the embodiments are not limited to specific forms of the illustrated area, and, for example, include variation in form by the manufacturing process thereof.

[0043] Hereinafter, a cap according to an embodiment of the present disclosure will be described in detail with reference to the accompanying drawings.

[0044] FIGS. 3A to 3F are views illustrating a process of manufacturing a crown of a cap according to an embodiment of the present disclosure.

[0045] The cap according to an embodiment of the present disclosure includes a crown part manufactured by connecting a plurality of crown panels (formed by coupling a plurality of crown panels 104 and 105), a visor part attached to a lower end of the crown part, and a sweatband part attached to an inner lower end of the crown part. The crown part is a part that covers a wearer's head and is made by connecting the plurality of crown panels 104 and 105. The crown part is dome shaped, a lower portion of which is open. A top button is attached to an apex of an uppermost portion of the crown part, such that a shape of the crown part may be fixed.

[0046] In addition, the visor part is attached to a lower portion of the crown part and serves to block sunlight or avoid direct sunlight. The visor part may protrude forward from a front surface of a lower end of the crown part. Or the visor part may be formed along the entire periphery of the lower end of the crown part.

[0047] The plurality of crown panels 104 and 105, which constitutes the crown part of the cap according to the embodiment of the present disclosure, may be connected to one another by sewing.

[0048] As illustrated in FIG. 3A, outer panels 102 are prepared by fabric cutting into a design pattern predetermined to form the crown. In addition, lining panels 101 are prepared by cutting a base panel that is woven with thick filaments, each of which is smaller than a corresponding outer panel.

[0049] In this case, the outer panel 102 may be made of any one of synthetic fiber and natural fiber or a blend thereof. In addition, the outer panel 102 may be made of polyester or nylon or made of any one of cotton, rayon, and wool or a blend thereof.

[0050] As illustrated in FIG. 3B, the lining panels (base panels) 101 each are attached to the outer panels 102 at predetermined intervals. The lining panel 101 may be variously modified depending on shapes and functions of the cap product. However, the lining panel 101 to be located at the front center of the cap needs to be designed smaller to keep a predetermined distance from each of the lateral edges of the outer panel 102.

[0051] As illustrated in FIG. 3C, in a state in which at least two crown panels 104 and 105, which are adjacent to each other among the plurality of crown panels, overlap each other, first sewing 106 is performed in a line along the edge of outer panels 105a and 105b at predetermined intervals.

[0052] As illustrated in FIG. 3D, the first sewing 106 couples the outer panels 105a and 105b as it is performed at a predetermined distance from the edge of the outer panels 105a and 105b of the crown panel. The first sewing 106 does not couple lining panels 104a and 104b. The first sewing 106 may be performed at a prearranged distance from the edge of the outer fabric panels 105a and 105b.

[0053] As illustrated in FIG. 3E, in a state in which the adjacent crown panels 104 and 105 are deployed, the ends of the coupled outer panels 105a and 105b are folded each toward opposite sides of the crown panels 104 and 105 that are deployed, such that seam portions 107a and 107b are formed. The seam portions 107a and 107b are formed side by side, by being folded toward opposite directions, and a seam cover tape 108, which is mainly made of a fiber material and has a width that may cover the seam portions 107a and 107b, is attached to surround the seam portions 107a and 107b, and then second sewing 109 is performed along both edges of the seam cover tape 108.

[0054] The seam cover tape 108 may have a thickness of about 0.1 mm to 1.0 mm and have a width wider than the sum of each width of the seam portions 107a and 107b. The seam cover tape 108 may have a width of about 15 mm to 32 mm.

[0055] In addition, the seam cover tape 108 may be made of any one of synthetic fiber and natural fiber or a blend thereof.

[0056] As illustrated in FIG. 3F, in the state in which the adjacent crown panels 104 and 105 are deployed, the seam cover tape 108, the seam portions 107a and 107b, the lining panels 104a and 104b, and the outer panels 105a and 105b may be fixed by the second sewing 109.

[0057] For a better aesthetic impression, the seam cover tape 108 surrounds the seam portions 107a and 107b, and both edges of the seam cover tape 108 are sewed 109. The seam portion of the cap manufactured as described above is formed as a single layer without the lining panel. Therefore, a thickness of the seam portion may be reduced, thereby producing a smooth surface, and improving the wearing comfort as opposed to the construction produced by the existing manufacturing method in which the seam portion normally consists of two layers including a base panel and increases a thickness. In addition, when the cap manufacturing process includes adding embroidery for ornament, like a logo, the method provides a significant improvement in productivity and quality as it lowers force applied against a needle of an embroidery machine.

[0058] FIGS. 4A to 4F are views illustrating a process of manufacturing a crown of a cap according to another embodiment of the present disclosure.

[0059] As illustrated in FIG. 4A, a crown panel 30 corresponding to the front of the cap product may be configured as a single panel. That is, the crown panel 30 may be configured as a single panel which is split at the upper half and appears to be two crown panels that are adjoined to each other at the lower half.

[0060] As illustrated in FIG. 4B, outer panels 205 are prepared by cutting an outer fabric 202 into a predetermined shape that corresponds to the front crown portion of the cap. In addition, lining panels 204 are prepared by cutting a base panel 201, which is woven with filaments, into a shape that is smaller by a predetermined size than the outer panel 205.

[0061] As illustrated in FIG. 4C, the outer panel 205 and the lining panel 204, after having been cut out, are bonded together, to overlap each other at predetermined position. The lining panel 204 may be variously modified depending on shapes and functions of the cap product. However, the lining panel 204 to be located in the front portion of the cap crown needs to be designed smaller to keep a predetermined distance from the lateral edges of the outer panel 205, thereby forming a seam portion at the center of the front portion of the crown part.

[0062] As illustrated in FIG. 4D, in a state in which the crown panel, formed by bonding the outer panel 205 and the lining panel 204, is folded in half, the upper split portion of the outer panel 205 may be connected by first sewing 206 that is performed next to the edge of the lining panel 204 at predetermined intervals.

[0063] As illustrated in FIG. 4E, seam portions 207a and 207b are folded in opposite directions, on top of which a seam cover tape 208 mainly made of fiber is placed to cover. The seam portions 207a and 207b are surrounded by the tape 8 that is wider than the width of the seam portions 207a and 207b, and then second sewing 209 is performed along both edges of the seam cover tape 208. The ends of the coupled portion of the outer panel 205 are folded toward opposite directions of the crown panel that is deployed, such that the seam portions 207a and 207b are defined. The seam cover tape 208 is set to surround the seam portions 207a and 207b by sewing.

[0064] Meanwhile, as illustrated in FIG. 4F, the seam portion 207c may be formed only at one side of the crown panel that is deployed as both ends of the coupled portion of the outer panel 205 are leaned toward the same direction. The seam portion 207c is defined at one side of the crown panel that is deployed, and is surrounded by the seam cover tape 218 having a width wider than a width of the seam portion 207c. And sewing 219 is performed along both edges of the seam cover tape 218.

[0065] FIG. 5 is a flowchart that lays out a manufacturing process of a cap according to an embodiment of the present disclosure.

[0066] With reference to FIGS. 3A to 3F and 5, according to a method of manufacturing the cap according to the embodiment of the present disclosure, the first step is to cut out a plurality of first panels which constitute the outer fabric (S101). The plurality of first panels is cut into a design pattern predetermined to form the crown.

[0067] The second step is to cut out a plurality of second panels which constitute the lining (S102). The plurality of second panels, each being a base panel woven with thick filaments, is cut out smaller than the corresponding first panel.

[0068] The third step is to prepare a plurality of third panels which constitute the crown part of the cap by bonding the first and second panels (S103).

[0069] The fourth step is to connect at least two third panels, which are adjacent to each other among the plurality of third panels, by the first sewing (S104). The first sewing is performed right next to the edge of the second panel.

[0070] The fifth step is to place a seam cover tape to cover a first sewing portion and a seam portion that is formed by deploying the connected third panels and to surround the seam portion thereafter (S105). In the state in which the connected third panels are deployed, the ends of the first panels are folded to form the seam portion which is surrounded by the seam cover tape having a width that may cover and surround the seam portion.

[0071] Lastly, second sewing is performed on the seam cover tape and the third panels (S106). The second sewing is performed along both edges of the seam cover tape, which is to fix the seam cover tape, the seam portion, the first panel, and the second panel, all together.

[0072] The aforesaid steps are followed repeatedly to manufacture the crown part of the cap according to the embodiment of the present disclosure.

[0073] Thereafter, further steps are conducted to produce a complete unit of a cap, which are attaching a sweatband part to an inner periphery of the lower end of the crown part; attaching a top button to an apex of an uppermost portion of the crown part; attaching a visor part to an outer portion of the lower end of the crown part; and adding embroidery on an outer surface of the third panels.

[0074] FIG. 6 is a flowchart that lays out a manufacturing process of a cap according to another embodiment of the present disclosure.

[0075] With reference to FIGS. 4A to 4F and 6, according to a manufacturing method of a cap in another embodiment of the present disclosure, the first step is to cut out a first panel which constitutes an outer fabric (S201). The first panel is cut into a design pattern predetermined to form the crown.

[0076] The second step is to cut out a second panel which constitutes a lining (S202). The second panel, being a base panel woven with thick filaments, is cut out smaller than the corresponding first panel.

[0077] The third step is to prepare a third panel which constitutes the crown part of the cap by bonding the first and second panels (S203).

[0078] The fourth step is to connect the upper split portion of the third panel by first sewing (S204).

[0079] The fifth step is to place a seam cover tape to cover the first sewing portion and a seam portion that is formed by deploying the connected portion of the third panel and to surround the seam portion thereafter (S205).

[0080] Lastly, second sewing is performed on the seam cover tape and the third panel (S206). The second sewing is performed along both edges of the seam cover tape, which is to fix the seam cover tape, the seam portion, the first panel, and the second panel, all together.

[0081] The above steps are followed repeatedly to manufacture the crown part of the cap according to another embodiment of the present disclosure.

[0082] Thereafter, further steps are conducted to produce a complete unit of a cap, which are attaching a sweatband part to an inner periphery of the lower end of the crown part; attaching a top button to an apex of an uppermost portion of the crown part; attaching a visor part to an outer portion of the lower end of the crown part; and adding embroidery on an outer surface of the third panel.

[0083] Meanwhile, Tables 1 to 3 below show seam thickness measurements depending on the cap manufacturing methods: the present disclosure versus the traditional method.

[0084] In this case, Table 1 shows measurements when a cap is manufactured by using a fabric made of polyester-rayon blended yarn and having a thickness of 0.5 mm and warp-weft density of 9462/inch (the warp being 94 yarns per inch and the weft being 62 yarns per inch). In addition, Table 2 shows measurements when a cap is manufactured by using a fabric made of polyester spun yarn and having a thickness of 0.6 mm and warp-weft density of 10472/inch. In addition, Table 3 shows measurements when a cap is manufactured by using a fabric made of cotton-polyester blended yarn and having a thickness of 0.4 mm and warp-weft density of 11256/inch.

TABLE-US-00001 TABLE 1 Classification General sewing Present disclosure Seam thickness (mm) 3.10 2.05

TABLE-US-00002 TABLE 2 Classification General sewing Present disclosure Seam thickness (mm) 3.80 2.45

TABLE-US-00003 TABLE 3 Classification General sewing Present disclosure Seam thickness (mm) 2.80 1.95

[0085] With reference to Tables 1 to 3, it can be determined that the seam thickness of the cap made by the manufacturing method of the present disclosure is much less than the seam thickness of the cap made by the general sewing method illustrated in FIGS. 2A to 2E.

[0086] Meanwhile, Table 4 below shows differences in productivity during the embroidery process for ornament according to the cap manufacturing methods.

[0087] Table 4 shows differences in productivity during the embroidery process conducted over the panel-connecting portion depending on the cap manufacturing methods when a cap is manufactured by using a fabric made of a polyester-rayon blended, 30'S double yarn and having a thickness of 0.5 mm and warp-weft density of 9462/inch. In this case, the 30'S double yarn is a yarn made by twisting two stands of yarn each having a thickness that measures 30 m per gram.

TABLE-US-00004 TABLE 4 Classification General sewing Present disclosure Occurrence of embroidery 12 0 thread breakage (1pc, number of times) Time taken for 1 pc 2441 1910 production (minute, second) Daily production (8 Hrs, 20 393 pcs 448 pcs HEAD)

[0088] The method according to the present disclosure, as shown in Table 4, proves no occurrence of embroidery thread breakage during the embroidery process when manufacturing a cap unit, and it can be determined that occurrence of embroidery thread breakage is noticeably reduced when compared to the general sewing method. In addition, by the method according to the present disclosure, it takes 19 minutes and 10 seconds to produce one piece of embroidery ornament for a cap unit, which calculates daily production of about 448 cap units and about 13% of productivity improved in comparison with the general sewing method.

[0089] As described above, according to the embodiment of the present disclosure, the crown panels each consist of the lining panel and the outer panel, which are designed in different sizes, and, when connected to form the crown of the cap, the seam portion where the crown panels are connected is formed to be thin, thereby producing a smooth surface and improving the wearing comfort.

[0090] In addition, to the method can improve both productivity and quality as it prevents needle or thread breakage of the embroidery machine which often occurs during the embroidery process.

[0091] In addition, any materials are suitable for this method, natural fiber as well as synthetic fiber, which means that a wide range of choice in style can be offered to consumers.

[0092] While the exemplary embodiments of the present disclosure have been described, the present disclosure is not limited to the embodiments. The present disclosure covers all modifications that can be easily made from the embodiments of the present disclosure by those skilled in the art and considered as being equivalent to the present disclosure.

DESCRIPTION OF SYMBOLS

[0093] 101, 104a, 104b, 204: Lining panel [0094] 102, 105a, 105b, 205: Outer panel [0095] 104, 105: Crown panel [0096] 106, 206: First sewing [0097] 107a, 107b, 207a, 207b, 207c: Seam portion [0098] 108, 208: Seam cover tape [0099] 109, 209: Second sewing