Patent Application
20250127251
This application claims priority to and the benefit of Korean Patent Application No. 10-2023-0141483 filed in the Korean Intellectual Property Office on Oct. 20, 2023, the entire contents of which are incorporated herein by reference.
The present disclosure relates to a cap and a method of manufacturing the same, and more particularly, to a cap, which includes a visor and a crown manufactured by connecting a plurality of panels, and a method of manufacturing the same.
In general, as illustrated in
The crown 10 of the cap having a hemispherical shape is manufactured by connecting a plurality of panels. In particular, as illustrated in
In particular, for the lining as applied above, a woven fabric made of chemical fibers with 800 deniers or more is commonly used to maintain a shape of a cap product. And the lining, being very thick and rigid, forms a portion that is further thicker and stiffer when the seam portions are folded thereupon, which further degrades wearing comfort.
In addition, the increased thickness of the seam portions causes a resistance load during the embroidery process and a needle or a thread of an embroidery machine often breaks, thereby causing lower productivity and embroidery quality. It is not a minor problem as embroidery is the most widely used way of ornament for cap products for brand indication and a better aesthetic impression.
The present disclosure attempts to provide a cap and a method of manufacturing the same, which are applicable to any materials and capable of minimizing a thickness of a connection portion between panels that constitute a crown and improving wearing comfort.
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.
The first sewing may be performed in a state in which the panels, which are adjacent to each other among the plurality of crown panels, overlap each other.
The first sewing may couple the outer panels at a distance spaced apart from an edge of the crown panel.
In a state in which the adjacent crown panels are deployed, ends of the coupled outer panels may be leaned toward at least one side of the crown panel that are deployed, such that a seam portion is formed.
In the state in which the adjacent crown panels are deployed, a seam cover tape may be attached in a length direction of the crown panel to cover and surround the first sewing portion and the seam portion.
The seam cover tape may have a thickness of from 0.1 mm to 1.0 mm.
The seam cover tape may have a width wider than a width of the seam portion.
The seam cover tape may be made of any one of synthetic fiber and natural fiber or a blend thereof.
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 may be fixed by second sewing.
The outer panel may be made of any one of synthetic fiber and natural fiber or a blend thereof.
The outer panel may be made of polyester or nylon.
The outer panel may be made of any one of cotton, rayon, and wool or a blend thereof.
A crown part panel corresponding to a front of the cap may be configured as one crown 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, and the upper split portion of the one crown panel may be connected by sewing after the one crown panel is folded in half.
The crown panel may be folded outwards so that the surface of the outer panel overlaps half and half.
The sewing may be performed to couple the upper split portion of the outer panel at a distance spaced apart from an edge of the crown panel.
In the state in which the panel is deployed, ends of the coupled portion of the outer panel may be folded each toward opposite sides of the panel that is deployed, such that a seam portion is formed.
In the state in which the panel is deployed, ends of the coupled portion of the outer panel may be leaned toward one side of the crown panel that is deployed, such that a seam portion is formed.
Another embodiment of the present disclosure provides a method of manufacturing a cap, the method including: 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 constitutes the crown part of the cap, by attaching the first and second panels; connecting at least two of the 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 that 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.
The method may further include: 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.
Still another embodiment of the present disclosure provides a method of manufacturing a cap, the method including: 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 half of the third panel by first sewing; placing a seam cover tape to cover a first sewing portion and a seam portion that is formed by deploying the connected third panel, and surrounding the seam portion; and performing second sewing on the seam cover tape and the third panel.
The method may further include: 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.
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.
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 as conducted in a traditional manner.
In addition, any materials, natural fiber as well as synthetic fiber, are suitable for this method, which means that a wide range of choice in style can be offered to consumers.
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.
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.
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.
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.
Hereinafter, a cap according to an embodiment of the present disclosure will be described in detail with reference to the accompanying drawings.
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.
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.
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.
As illustrated in
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.
As illustrated in
As illustrated in
As illustrated in
As illustrated in
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.
In addition, the seam cover tape 108 may be made of any one of synthetic fiber and natural fiber or a blend thereof.
As illustrated in
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.
As illustrated in
As illustrated in
As illustrated in
As illustrated in
As illustrated in
Meanwhile, as illustrated in
With reference to
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.
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).
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.
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.
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.
The aforesaid steps are followed repeatedly to manufacture the crown part of the cap according to the embodiment of the present disclosure.
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.
With reference to
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.
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).
The fourth step is to connect the upper split portion of the third panel by first sewing (S204).
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).
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.
The above steps are followed repeatedly to manufacture the crown part of the cap according to another embodiment of the present disclosure.
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.
Meanwhile, Tables 1 to 3 below show seam thickness measurements depending on the cap manufacturing methods: the present disclosure versus the traditional method.
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 94×62/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 104×72/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 112×56/inch.
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
Meanwhile, Table 4 below shows differences in productivity during the embroidery process for ornament according to the cap manufacturing methods.
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 94×62/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.
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.
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.
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.
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.
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.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10-2023-0141483 | Oct 2023 | KR | national |
