METHOD FOR MANUFACTURING CROWN OF CAP

CROSS REFERENCE TO RELATED APPLICATION

The present application claims priority to Korean Patent Application No. 10-2017-0101879 filed on Aug. 10, 2017, the entire contents of which is incorporated herein for all purposes by this reference.

BACKGROUND OF THE INVENTION
Field of the Invention

The present invention generally relates to a method for manufacturing a cap and, more particularly, to a method for manufacturing a crown.

Description of the Related Art

A conventional art to manufacture a cap is described below.

As seen from FIG. 9, according to the conventional art, the crown 10 is a portion of covering a wearer's head. Generally, six fabric sections 10-1, 10-2, 10-3, 10-6, 10-5, and 10-3 are combined with each other by sewing. Here, the fabric sections 10-3 and 10-5 in the back are not seen.

Conventionally, it is well-known that two fabric sections 10-1 and 10-2 in the front, among the above-described fabric sections, constitute a pair, and two fabric sections 10-5 and 10-6 in the back constitute a pair.

Thereafter, they face a central fabric section 10-3 in the left and a central fabric section 10-4 in the right respectively and are sewn together.

In this case, the two fabric sections constituting a pair forms a first sewn coupling 12 by sewing, and this coupling by sewing is usually performed.

These fabric sections form a crown, to which a brim 20 is attached, thereby providing a manufactured cap.

Also, a second sewn coupling 14 is performed again in left and right sides of the first sewn coupling 12.

The conventional art shows that a plastic rib is inserted into a sewn coupling region of the left fabric section 10-1 in the front and the left fabric section 10-3 in the center and a sewn coupling region of the right fabric section 10-2 in the front and the right fabric section 10-4 in the center, among the six fabric sections constituting the crown 10.

In the conventional art, an example showing a combination relation of the plastic rib 18 and each of the fabric sections is suggested in an enlarged sectional diagram of FIG. 9.

Here, it is illustrated that the plastic rib 18 is located in the sewn side of the front right fabric section 10-2 and the central right fabric section 10-4, and they are surrounded with a sewn coupling fabric 16 and finished by the second sewn coupling 14.

However, the cap constructed in this way causes inconvenience because a plastic rib should be separately inserted, and there is also inconvenience because a place in which the plastic rib is positioned is to be finely sewn twice.

In addition, the cap carries uncouthness in the external appearance of the cap as the plastic rib becomes thick. Accordingly, there is a defect because the cap's appearance is not beautiful.

There is also a defect that the plastic rib 18 is detached from the cap as time goes by.

Also, there is a defect that the shape of the plastic rib 18 is deformed due to external temperature.

In this regard, appearance of a more desirable cap is required.

Accordingly, the present invention is directed to solving the problems as described above.

The foregoing is intended merely to aid in the understanding of the background of the present invention, and is not intended to mean that the present invention falls within the purview of the related art that is already known to those skilled in the art.

DOCUMENTS OF RELATED ART

(Patent Document 1) Korean Patent No. 10-1104372 issued on Jan. 16, 2012; and

(Patent Document 2) Korean Patent No. 10-1302399 issued on Aug. 27, 2013.

SUMMARY OF THE INVENTION

The present invention has been made keeping in mind the above problems occurring in the related art. The present invention according to a first exemplary embodiment has the following objectives:

First, as there is no trouble to insert and sew the plastic, and no sewing that deteriorates efficiency of the work is required, productivity in manufacture of the cap will increase.

Second, a defect that the cap becomes unattractive in external appearance because the plastic rib 18 becomes thick will be solved.

Third, the original form of the cap will be maintained for a long time because the plastic rib 18 is not detached from the cap

Fourth, as a defect that the plastic rib 18 is deformed due to hot temperature will be solved, there will be no danger that the plastic rib 18 is deformed due to temperature.

In addition to the above-described objectives of the first exemplary embodiment of the present invention, the second exemplary embodiment thereof has the following additional objectives:

Fifth, as a phenomenon that the front side of the crown becomes very thick by attaching the fabric to a thick buckram, cutting and sewing the front left and right portions of the crown will be prevented, generation of unevenness in the seam line will be prevented.

Sixth, as the crown according to the present invention is not processed by gluing, the front portion of the crown will not be twisted. Also, the present invention is intended to prevent generation of uneven creases.

Also, due to the non-use of glue, there is no danger that the glue leaks into the inside of the fabric.

Seventh, as no embroidery is seen inside the crown, the inside of the cap will be neat.

Eighth, as the defects of the conventional art are compensated, little or no deformation of the cap will occur as time goes by. In particular, the front side of the crown will be very stable as compared to the cap manufactured by the conventional art, whereby long-term beautiful appearance can be achieved.

Ninth, as little or no unevenness will be generated in the seam portion of the crown, any logo can be printed on the front portion of the crown by a printer as desired. Accordingly, printing the logo in large quantities can be achieved.

Tenth, as the front portion of the crown will be more uniform in thickness, it can be ironed uniformly.

Eleventh, the cap can be manufactured to be high-quality.

Twelfth, prevention of an inner fabric and an outer fabric of the crown from separating because of different contraction and expansion factors as winter and summer pass is achieved. Accordingly, no deformation will occur even though time passes.

Thirteenth, as the seam portion of the crown is thin in thickness, the present invention prevents any needle of the needle bar from being broken.

In order to solve the problems as described above, the objectives of the present invention will be achieved through the following manufacturing method:

In the first exemplary embodiment of the present invention, a method for manufacturing a cap configured to have a crown includes:

coupling a buckram to which glue is attached to a fabric that forms the crown of the cap;

preparing a front left fabric section and a front right fabric section among the six fabric sections constituting a crown that will cover a wearer's head, from the coupled fabric;

preparing a first fabric section by connecting the front left fabric section and the front right fabric section by sewing; and

applying predetermined heat and pressure to a heating apparatus taking a part of a crown shape, thereby attaching the first fabric section more firmly.

The method further includes attaching a logo to the front portion of the cap or constructing the logo through broidery subsequent to preparing the fabric section.

In the course of preparing the first fabric section, the font left fabric section and the front right fabric section are coupled by a first fabric section coupling band.

A cap is manufactured with the front portion of the crown prepared as described above.

In the second exemplary embodiment of the present invention, a method for manufacturing a crown of a cap without using buckram and glue employs the following method described below.

A part of a crown is completed through the steps of:

preparing a front left fabric section and a front right fabric section, which are fabric sections constituting the front portion of the crown, among the six sections of a fabric of the crown which is an outer of a cap and determines an external appearance of the cap put on a wearer's head;

preparing a third fabric section by sewing the front left fabric section and the front right fabric section together;

positioning and sewing a third fabric section coupling band inside the third fabric section based on a sewn coupling portion connected and coupled with the third fabric section, preventing any crease from being generated in the sewn coupling portion;

positioning a second fabric section inside the third fabric section, in order to maintain a partial shape of the crown;

preparing two fabric sections taking the same shapes as the front left fabric section and the front right fabric section which constitute the third fabric section;

preparing a second fabric section by sewing the two fabric sections together;

positioning and sewing a second fabric section coupling band inside the second fabric section, preventing any crease from being generated in a sewn coupling portion connected and coupled with the second fabric section;

positioning the third fabric section outside and the second fabric section inside; and

attaching by sewing circumference edges of the second fabric section and the third fabric section,

wherein it may be desirable to position a part of the crown in a heating apparatus, to which certain heat and pressure are applied, thereby positioning the second fabric section and the third fabric section more closely to each other.

It may be desirable to further include attaching a logo to the third fabric section or constructing the logo through embroidery prior to attaching by sewing the third fabric section outside and the second fabric section inside.

It may also be desirable that a material of the second fabric section is buckram.

The method according to the first exemplary embodiment of the present invention is advantageous as follows:

First, productivity in production of the cap can be increased because there is no need to perform a sewing operation after insertion of a plastic rib, which reduces the efficiency of the work.

Second, a defect such that the external appearance of the cap becomes unattractive because of the plastic rib will be solved.

Third, the original form of the cap can be maintained for a long time even without the plastic rib 18.

Fourth, a defect such that the plastic rib 18 is deformed due to high temperature is solved, whereby the plastic rib 18 has no risk of being deformed due to temperature.

Subsequent to the above-described effects of the first exemplary embodiment, the method according to the second exemplary embodiment of the present invention has the following additional effects:

Fifth, a phenomenon that unevenness is generated in the seam line of the coupled portion of the front portion of the crown can be prevented to a considerable degree.

Sixth, the front portion of the crown will not be twisted even though time goes by, and generation of uneven creases can be prevented.

Seventh, as no embroidery can be seen inside the cap, the inside of the cap is neat, thus imparting tidiness in the beauty.

Eighth, as there is no or little unevenness in the front portion of the crown, a logo can be printed by a printer, thus it is advantageous that the logo can be printed in large quantities.

Ninth, as the front portion of the crown is more uniform in thickness, it is possible to make ironing uniform.

Tenth, the cap can be manufactured to be high-quality.

Eleventh, a phenomenon that an inner fabric and an outer fabric of the crown are separated because of different contraction and expansion factors as winter and summer pass can be prevented. According to the present invention, no deformation is caused even though time passes by.

Twelfth, a phenomenon that the needle of the needle bar is broken is prevented.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other objectives, features and other advantages of the present invention will be more clearly understood from the following detailed description when taken in conjunction with the accompanying drawings, in which:

FIG. 1a is a view showing that a fabric of a cap coupled with a buckram is cut into fabric sections, to manufacture a crown;

FIG. 1b is a view showing the buckram which is an inner fabric section to which glue is attached;

FIG. 1c is a view showing an outside of FIG. 1b;

FIG. 1d is a view showing a front portion of a crown that couples two fabric sections;

FIG. 1e is a view showing the inside of FIG. 1d in which the two fabric sections are coupled by sewing;

FIG. if is a view showing that the fabric sections for the crown attached by glue is again better attached with heat at 150 to 180° C. and pressure applied thereto;

FIG. 2a is a view showing an outside of the front portion of the crown in a process of attaching a logo 710 to the front portion of the crown;

FIG. 2b is a view showing the inside of FIG. 2a;

FIG. 3a is a view showing the outside of FIG. 2b showing an external shape 810 of the finished cap;

FIG. 3b is a view showing the inside 910 of the finished cap constructed as described above;

FIG. 4a is a view showing a fabric attached to the inside of the front portion of the crown that is buckram;

FIG. 4b is a view showing a fabric section coupled with the buckram;

FIG. 4c is a view showing the rear side of FIG. 4b;

FIG. 5a is a view showing fabric sections of the crown of the cap;

FIG. 5b is a view showing the fabric sections overlapped and backstitched;

FIG. 5c is a view showing that the fabric sections of FIG. 5b are unfolded, the inside of which is backstitched with a coupling band applied thereon;

FIG. 5d is a view showing the rear side of FIG. 5c;

FIG. 5e is a view showing a state where a logo is applied on a third fabric section;

FIG. 5f is a view showing a rear side of FIG. 5e;

FIG. 6a is a view showing that a second fabric section and a third fabric section are coupled by sewing;

FIG. 6b is a view showing the front side of FIG. 6a;

FIG. 6c is a view showing that FIG. 6a is positioned on a heating apparatus;

FIG. 6d is a view showing that a upper plate and a lower plate of the heating apparatus of FIG. 6d are coupled;

FIG. 7 is a view showing an external appearance of the front portion of the crown after having passed through the step d of FIG. 6;

FIG. 8 is a view showing a cap manufactured with the front portion of the crown; and

FIG. 9 is a view showing a conventional art.

DETAILED DESCRIPTION OF THE INVENTION

Hereinbelow, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings. Throughout the drawings, the same reference numerals will refer to the same or like parts.

First Exemplary Embodiment

The first exemplary embodiment of the present invention covers FIGS. 1a to 3b.

To achieve the first to fourth objectives of the present invention as described above, the method is configured as described below.

This method is to solve those problems of the conventional an.

A fabric attached to the front portion of the crown inside the cap is woven with a filament-yam of nylon system. It is called mono lining or backing buckram, that is, adhesive interlining.

As compared to other fabrics, the fabric has a strong force to maintain its original form.

The first exemplary embodiment will be explained below, based on FIG. 1a.

In FIG. 1a, a fabric is attached to the buckram and the crown of the cap at certain pressure and temperature before cutting out it into fabric sections.

That is, the above operation is to attach glue of solid form to be melt with heat to a buckram type fabric attached to the inside of the crown, to prevent the crown falling under the two front portions among six fabric sections of the crown from being wrinkled.

After attaching the buckram to the fabric of the cap, the cutting operation of FIG. 1a is performed.

More specifically, the above operation will be described below.

A fabric to construct a cap is prepared and a buckram type fabric is also prepared.

Thereafter, glue is attached to the buckram and the buckram is coupled with the fabric to construct the cap.

After then, an operation to cut out fabric sections falling under a front left fabric section and a front right fabric section constituting a front portion, among the six fabric sections of the crown, from the coupled fabric is performed.

In FIG. 1b, a buckram fabric section 110 which is an inner fabric section to which glue is attached is prepared and a fabric section falling under the front portion of the crown, which is a front crown fabric section 210 of the cap in FIG. 1c, are prepared.

FIG. 1c shows a rear side of FIG. 1b.

As observed in FIG. 1a, two fabric sections are attached, and FIGS. 1b and 1c represent the inside and the outside thereof.

As seen in FIG. 1d, a first fabric section is prepared by coupling two front crown fabric sections.

FIG. 1e shows the inside of FIG. 1d.

This figure shows two fabric sections coupled with a sewing yarn.

In FIG. 1e, two crown fabric sections are coupled by attaching a first fabric section coupling band 410 which is a band coupling two crown sections.

In FIG. 1f, heat at 150 to 180° C. and pressure are again applied to the first fabric section 310 that attaches the buckram to a fabric of constructing the cap with glue, by applying heat and pressure at the upper plate 610 and the lower plate 510 of the heating apparatus, so that they can be well attached.

FIG. 2a shows a process of attaching a logo 710 to the front portion of the crown, showing the outside of the crown.

FIG. 2b shows the inside of FIG. 2a. The rear side into which the logo 710 is applied is shown.

FIG. 3a shows a finished cap 810 showing the outside of FIG. 3b.

FIG. 3b shows the inside 910 of the finished cap constructed as described above.

The cap is manufactured with the front portion of the crown manufactured by the above-described method.

Second Exemplary Embodiment

In order to achieve the fifth to thirteenth objectives subsequent to the first to fourth objectives as described above, the present invention is configured as follows:

To settle the defects of the background art and that of the first exemplary embodiment, the manufacturing method according to the second exemplary embodiment is described below:

In the first exemplary embodiment, the inside of the crown presses the wearer's forehead because of a portion protruded due to the logo, and it also makes the cap poor in terms of beauty.

The second exemplary embodiment covers FIGS. 4a to 8.

The second exemplary embodiment further improves the first exemplary embodiment to overcome the defect thereof.

As seen in FIGS. 1d and 2a, as the front portion of the crown is manufactured after coupling two fabric sections is manufactured, a protrusion is formed in the front portion of the crown constructed by connecting the central portions, being defective because the cap is not smooth.

In this regard, there has been an overwhelming of demand for improvement from consumers.

However, such a defect as described above has not been solved to date.

The second exemplary embedment of the present invention solves this defect.

According to the first exemplary embodiment, two fabrics are only attached by sewing in the first needlework, but they are actually sewn in four folds in the first needlework sewn into two fabric.

However, when the two fabric sections are connected and sewn with the first fabric section coupling band 410 in the inside of the fabric of the cap, the end portions of the two fabrics are surrounded and sewn with the first fabric section coupling band 410, thus six folds of the fabrics are actually sewn.

Because of this, a phenomenon that the needle is broken often occurs. In particular, the needle can be further easily broken when a logo is embroidered into the cap.

In addition, the thickness of the backing buckram is two folds, but the backing buckram is actually constructed thickly more twice than a general fabric of the cap. Accordingly, the above-described six-fold sewing is made when the front portion of the cap is sewn, but it is actually likely to sew the crown with thickness as same as eight folds or more.

Also, in the first exemplary embodiment, as a part of glue attaching the buckram to the fabric of the cap processed by glue is partially detached as time goes by, and only a part of the glue remains, creases occur at the front portion of the crown which becomes twisted or uneven causing the cap to be not good in terms of beauty.

The second exemplary embodiment is effective in preventing generation of unevenness in the seam line with respect to the coupled portion of the front portion of the crown.

In effect, as no glue is used, the front portion of the crown is not twisted and generation of uneven creases is prevented as time goes by.

Also, as no embroidery is seen in the inside, the inside of the cap is neatly constructed, producing an effect of clarity in the beauty.

As the front portion of the crown has no unevenness, the logo can also be printed by a printer and thus there is an advantage that the logo can be printed in many quantities.

As the front crown portion is more uniform in thickness, there is an effect that the ironing can be uniformly performed.

There is also an effect that the cap can be manufactured to be high-quality.

A phenomenon that an inner fabric and an outer fabric of the crown may be separated due to different contraction and expansion factors as winter and summer pass can be prevented. Also, no deformation is caused even though time passes.

The present invention can also completely prevent the wearer's head from contacting the glue, which is caused when the glue comes out from the inside of the fabric.

The defect such that any embroidery is seen in the inside and the protruded portion of the embroidery portion contacts the wearer's forehead when the wearer wears the cap is also solved.

The method according to the second exemplary embodiment to achieve the above-described objectives will be described as follows:

The method will be described in reference to FIGS. 4a to 4c.

To maintain the shape of the crown, two buckram fabric sections 120 corresponding in shape to shapes of the front left fabric section and the front right fabric section of the crown are coupled in the inside of the crown, wherein a process of preparing a second fabric section 320 sewn with a second fabric section coupling band 420 is shown.

That is, the method has a process of preparing the front left fabric section and the front right fabric section which are buckram fabric sections 120 of the crown to be put on the wearer's head.

Here, in addition to the buckram, any fabric if it is flexible or thermally elastic may be acceptable.

FIGS. 5a to 5f will be described below.

As seen in FIG. 5a, an outer fabric of the cap determining an external appearance of the cap is sectioned into two fabric sections, wherein the front crown fabric sections 220 that are the front left fabric section and the front right fabric section are prepared.

In FIG. 5b, the two fabric sections prepared as described above are put together and connected by sewing.

In FIG. 5c, a third fabric section 330 prepared in FIG. 5b is again attached with a coupling band.

This process may be selectively performed.

As only thin fabric is sewn in preparing the third fabric section 330, the sewing is easy, and no force is applied to the needle. Accordingly, there is no defect that any needle is broken.

The sewn coupling portion 340 gives no or little trouble in the sewing because the thickness of the fabric is thin, and it is advantageous because fine needlework is possible. Also, any situation that the fabrics closely connected by sewing are separated is not generated.

The sewing portion 350 attaching the second fabric section coupling band 420 can further perform the concerned step, to prevent any crease from being generated in the front portion of crown by the sewn coupling portion 340.

This step may be added or deleted.

Advantageously, there is no indication that a gap 360 between the sewing portions 360 is unattractive.

As the fabric is thin, there is an effect that the fabric is stretched out in a line.

In this point, the second exemplary embodiment has a better effect than the first exemplary embodiment.

FIG. 5d will be described below. FIG. 5d shows the inside of FIG. 5c. This figure also shows a configuration that the third fabric section coupling band 430 is again sewn with the third fabric section 330.

This step may be performed selectively.

Next, FIG. 5e will be described.

A logo 720 is applied on the third fabric section 330 prepared as described above.

FIG. 5f shows the inside of FIG. 5e.

Here, a phenomenon that the needle is broken does not occur even when the logo is applied.

Application of the logo can be made any time selectively before or after the second fabric section is coupled with the third fabric section.

More preferably, after the logo is applied on the third fabric section, the second fabric section is connected to the third fabric section, making the inside of the cap neat. This can also serve to prevent generation of unevenness caused when the fabrics different in expansion and contraction factors are isolated from each other as time goes by.

Next. FIGS. 6a to 6d will be described below.

The present invention will be described in reference to FIGS. 6a and 6b.

After preparing the second fabric section 320, the method has a further step of connecting the third fabric section 330 and the second fabric section 320 by sewing.

That is, these figures show that the second fabric section is coupled with the rear side of the third fabric section by sewing after the logo 720 is embroidered in FIGS. 5e and 5f.

This step may be selectively performed.

Next, FIGS. 6c and 6d will be described below.

The third fabric section is positioned outside, and the second fabric section is positioned inside. Heat at temperature of 150 to 180° C. and pressure are applied to a heating apparatus 600 including an upper plate 620 and a lower plate 520, to allow the second fabric section 320 and the third fabric section 330 to be closely positioned to each other. Through this process, the front portion of the crown constituting a partial shape of the crown is manufactured.

A part of the crown constructed as described above is to make a part of the crown erect at the front portion of the cap and make it smooth.

The second fabric section 320 and the third fabric section 330 are coupled by the fabric section coupling bands 420 and 430 respectively.

It may be desirable to use the third fabric section 330 by connecting the front left and right fabric sections as they are, among the six fabric sections constituting the crown, without using the fabric section coupling band.

Here, it would be desirable to use a buckram as the material of the second fabric section 320.

Any material is acceptable if it is flexible or thermally elastic.

FIG. 7 shows the front portion of the crown prepared by FIG. 6d, making the front portion of the crown very beautiful.

Here, no glue is used. As the second fabric section and the third fabric section are closely coupled by heat, the shape of the crown can be maintained for a long time.

FIG. 8 shows that the front portion of the crown constructed as described above serves to make the cap have good shape in terms of beauty. The cap 820 manufactured in this manner is shown in FIG. 8.

It has been described that the buckram is used as the second fabric section, but it is also possible to use any fabric other than the buckram.

Terms or words used in the description and the claims of the present invention cannot be limited, for the purposes of interpretation, to general or lexical meanings. They shall be interpreted under the meanings and concepts compliant with the technical idea of the present invention based on the principle that the inventor(s) can define concept(s) of the toms as proper, to explain his/her own invention in the best way.

Although preferred embodiments of the present invention have been described for illustrative purposes, those skilled in the art will appreciate that various equivalents, modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims.

METHOD FOR MANUFACTURING CROWN OF CAP

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