U.S. patent application number 10/996390 was filed with the patent office on 2006-06-01 for method for stiffening headgear.
Invention is credited to Tai-Kuang Wang.
Application Number | 20060112475 10/996390 |
Document ID | / |
Family ID | 36566035 |
Filed Date | 2006-06-01 |
United States Patent
Application |
20060112475 |
Kind Code |
A1 |
Wang; Tai-Kuang |
June 1, 2006 |
Method for stiffening headgear
Abstract
A method for stiffening a headgear utilizes knitted thermo
polyester linings made of threads consisting of fine and soft
filaments extracted from thermo polyester pellets to sew with
ready-cut fabrics to form a headgear. Subsequently, the headgear is
heated by a mold such that the fiber of the linings will be
appropriately stiffened, thereby shaping an upstanding and neat
headgear as desired.
Inventors: |
Wang; Tai-Kuang; (Taipei,
TW) |
Correspondence
Address: |
LEONG C LEI
PMB # 1008
1867 YGNACIO VALLEY ROAD
WALNUT CREEK
CA
94598
US
|
Family ID: |
36566035 |
Appl. No.: |
10/996390 |
Filed: |
November 26, 2004 |
Current U.S.
Class: |
2/195.5 |
Current CPC
Class: |
A42B 1/0189 20210101;
A42C 1/08 20130101; A42B 1/02 20130101 |
Class at
Publication: |
002/195.5 |
International
Class: |
A42B 1/00 20060101
A42B001/00 |
Claims
1. A method for stiffening a headgear, including preparation of a
headgear composed of pluralities of cut fabrics, linings, a peak
and a sweatband, characterized in that: the linings are knitted by
thermo setting polyester threads, which are made from fine and soft
filaments extracted from thermo polyester pellets, and sewn with
the ready-cut fabrics, and then combined with the peak and the
sweatband to form a headgear; subsequently, the headgear together
with linings are heated by a mold, thereby shaping an upstanding
and neat headgear.
2. The method for stiffening a headgear according to claim 1,
wherein the linings and the ready-cut fabrics can be sewn together
one by one, such that the integral lining is sewn up at the front
piece of the crown.
3. The method for stiffening a headgear according to claim 1,
wherein the linings can be sewn piece by piece to form a crown
shape, and then integrally sewn to the crown at the peripheral edge
of the crown to form a full lining inside of the crown before the
sweatband is sewn to the crown.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field of the Invention
[0002] The present invention relates to a method for stiffening a
headgear, which is full of aesthetic feelings with a fixed shape.
Besides, as the stiffened linings are processed without adding any
harmful chemical, such as HCHO, the method of the invention is
especially applicable to the manufacturing of headgears.
[0003] 2. Description of the Prior Art
[0004] A conventional headgear is basically composed of a crown and
a hard peak. As the front side of the crown is the most apparent
portion, whether or not the headgear is neat, upstanding and good
looking depends on the expression of the front side of the
crown.
[0005] In the manufacturing of headgear of the prior art, in order
to make the headgear look upstanding and neat, the crown is adhered
with linings of various kinds. Since it is required that the
adhered linings must have certain rigidity, resin is generally used
as an adhesive in this respect. As shown in FIG. 1, in the
manufacturing of headgear of the prior art, a lining 10 is applied
with an adhesive of resin 11, such that the resin 11 is infiltrated
into the fiber of the lining 10. Upon being baked by a heating
device, the lining 10 along with the resin 11 will dry out and
becomes a hardened board. The hardened lining 12 is then integrally
adhered to and sewn with a ready-cut fabric 13 to form a front
piece of the crown, which is subsequently sewn to the front side of
the crown, such that the headgear will look upstanding and
neat.
[0006] However, there exists a disadvantage in the above-mentioned
headgear process, i.e. heating the resin adhesive will generate
HCHO which, being a colorless and easily melted irritating gas, is
harmful to human body, since it can be absorbed by human through
aspiratory system, and the solvent of HCHO, formalin, will be
absorbed through digestive system. Generally, formalin, a 35%-40%
HCHO solvent, is used as an antiseptic for soaking medical sections
and personal/animal specimens. HCHO is definitely harmful to human
body, since it can enter human body to connect with amine of
protein, and cause alteration of the protein, thereby disturbing
the metabolism of cells and seriously destroying cell organization.
According to international reports, when formalin has a density
exceeding 0.12 mg/m3, it will easily cause asthma in children.
Therefore, HCHO has been announced by IARC (International Agency
for Research on Cancer) as a suspectable carcinogen. In view of the
above, headgears composed of heated resin might cause diseases to
the users after long-term use.
[0007] In addition, infiltrating resin into the fabric will make
the fabric unventilated, rendering the user feel hot and constantly
sweat.
[0008] Accordingly, the inventor has disclosed a method for
stiffening a headgear, which would not generate HCHO during
process, and can produce a headgear of upstanding and neat shape
for safely used by the consumers.
SUMMARY OF THE INVENTION
[0009] The primary purpose of the present invention is to provide a
method for stiffening a headgear which can have an upstanding and
neat shape.
[0010] The secondary object of the invention is to provide a method
for stiffening a headgear, in which the linings of the headgear can
be stiffened without the application of a heated resin, thus
avoiding the occurrence of any poisoned material such as HCHO and
allowing the user to wear the headgear more safely.
[0011] A further object of the invention is to provide a method for
manufacturing a headgear which has better ventilation.
[0012] In addition, in view of the characteristic that thermo
setting polyester material will commence softening at a temperature
of around 80.degree. C. and become melted at around 100.degree. C.,
the soft and fine fiber can be melted and then cooled to form a
relatively thick and hard material, thereby allowing the headgear
to have a stiffening effect. Whereas general polyester can only be
melted at a higher temperature of 280.degree. C.; therefore, the
thermo setting polyester is comparatively applicable to the
headgear that requires a stiffening appearance.
[0013] To obtain the above objects, the invention utilizes the
knitted thermo polyester linings made of threads consisting of fine
and soft filaments extracted from thermo polyester pellets to sew
with the ready-cut fabrics, and then combined with the peak and the
sweatband to form a headgear. Subsequently, the headgear together
with linings is heated by a mold, thereby shaping an upstanding and
neat headgear.
[0014] The foregoing object and summary provide only a brief
introduction to the present invention. To fully appreciate these
and other objects of the present invention as well as the invention
itself, all of which will become apparent to those skilled in the
art, the following detailed description of the invention and the
claims should be read in conjunction with the accompanying
drawings. Throughout the specification and drawings identical
reference numerals refer to identical or similar parts. Many other
advantages and features of the present invention will become
manifest to those versed in the art upon making reference to the
detailed description and the accompanying sheets of drawings in
which a preferred structural embodiment incorporating the
principles of the present invention is shown by way of illustrative
example.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 shows applying a resin on the crown fabric according
to the prior art.
[0016] FIG. 2 shows sewing the hardened lining with the ready-cut
fabric according to the prior art.
[0017] FIG. 3 shows the process of sewing to combine two ready-cut
fabrics according to the present invention.
[0018] FIG. 4 is an exploded view of the front piece of the crown
according to the invention.
[0019] FIG. 5 is a perspective view of the front piece of the
crown.
[0020] FIG. 6 is a bottom view of the headgear made according to
the invention.
[0021] FIG. 7 shows the process of heating to stiffen the linings
according to the invention.
[0022] FIG. 8 shows the process of another embodiment according to
the invention.
[0023] FIG. 9 is a bottom view of the headgear made according to
another embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] The following descriptions are of exemplary embodiments
only, and are not intended to limit the scope, applicability or
configuration of the invention in any way. Rather, the following
description provides a convenient illustration for implementing
exemplary embodiments of the invention. Various changes to the
described embodiments may be made in the function and arrangement
of the elements described without departing from the scope of the
invention as set forth in the appended claims.
[0025] As shown in FIGS. 3 to 5, in the process of the present
invention, two ready-cut fabrics 20 are sewn together via a needle
30 and threads 31 to form a front piece 21 of a crown. While the
threads 31 are thermo setting polyester threads made from fine and
soft filaments extracted from thermo polyester pellets, the linings
are in form of a soft material. After the linings 40 are sewn
together with the front piece 21, they are further sewn with a peak
41 and a sweatband 41 to form a headgear 50 shape (as shown in FIG.
6). Still, the linings 40 at the inner side of the front piece 21
are soft and cannot make the headgear look upstanding and neat. As
such, an additional process for stiffening the headgear 50 is
further required.
[0026] As shown in FIG. 7, as the linings are formed by thermo
polyester filaments, it is necessary to apply a heating process to
obtain an appropriate rigidity. Such heating process requires a
mold 60, which is provided with a casing having pluralities of
steam outlets 61 and steam to be released from the outlets 61. The
headgear 50 is disposed on the top of the mold 60, such that the
linings 40 can be heated by the released steam and set by the mold
60. The temperature of the steam will make the thermo polyester
linings 40 gradually stiffened without generating a poisoned
material such as HCHO, and therefore allow the user to wear the
headgear more safely.
[0027] Referring to FIG. 8, showing another embodiment of the
invention, each of the ready-cut fabrics 20 can be sewn together
with each of the linings 40 and subsequently processed according to
the procedures as mentioned above to make the linings 40 stiffened,
thereby obtaining an upstanding and neat headgear.
[0028] In a further embodiment of the invention, the linings 40 can
be sewn together to form a crown shape, and integrally sewn with
the crown at the peripheral edge of the crown to form a full lining
inside of the crown before the sweatband is sewn to the crown.
[0029] In view of the above, the method for stiffening a headgear
according to the invention has the following advantages:
[0030] 1. As the linings are not applied with a heated resin
adhesive, no poisoned material such as HCHO will be generated to do
harm to the user's health.
[0031] 2. Before the headgear enters a stiffening process, the
linings maintain in a soft condition, which can permit the sewing
process easily proceeded, thus speeding the production.
[0032] 3. As the headgear is heated to stiffen and set the linings
right before it is out of the factory gate, it can stay in the most
upstanding status, eliminating transformation during the sewing
process and in-factory conveyance.
[0033] 4. The linings made according to the invention have
excellent ventilation and can make the user feel dry and
comfortable.
[0034] Concluded above, the invention discloses a method for
stiffening a headgear, which can eliminate the disadvantages
existing in the prior art that uses a heated resin as an adhesive.
The invention further provides a manufacture method which can
simplify the process, speed the manufacture and make the headgear
more upstanding and neat.
[0035] It will be understood that each of the elements described
above, or two or more together may also find a useful application
in other types of methods differing from the type described
above.
[0036] While certain novel features of this invention have been
shown and described and are pointed out in the annexed claim, it is
not intended to be limited to the details above, since it will be
understood that various omissions, modifications, substitutions and
changes in the forms and details of the device illustrated and in
its operation can be made by those skilled in the art without
departing in any way from the spirit of the present invention.
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