U.S. patent application number 11/104420 was filed with the patent office on 2006-09-21 for cap and manufacturing method thereof.
This patent application is currently assigned to Yupoong, Inc.. Invention is credited to Byoung-Woo Cho.
Application Number | 20060206982 11/104420 |
Document ID | / |
Family ID | 37008710 |
Filed Date | 2006-09-21 |
United States Patent
Application |
20060206982 |
Kind Code |
A1 |
Cho; Byoung-Woo |
September 21, 2006 |
Cap and manufacturing method thereof
Abstract
The present invention provides a cap and a manufacturing method
thereof having advantages of high elasticity, easiness in wearing,
and an enhanced productivity due to a simplified manufacturing
process. A cap of the present invention includes a crown portion
formed by overlapping of at least one stretchable fabric piece,
wherein the at least one fabric piece is made of a run-proof
material for preventing a run at a seam portion of the at least one
fabric piece, the seam portion being directly contactable to a head
of a wearer.
Inventors: |
Cho; Byoung-Woo;
(Yongin-city, KR) |
Correspondence
Address: |
STAAS & HALSEY LLP
SUITE 700
1201 NEW YORK AVENUE, N.W.
WASHINGTON
DC
20005
US
|
Assignee: |
Yupoong, Inc.
Seoul
KR
|
Family ID: |
37008710 |
Appl. No.: |
11/104420 |
Filed: |
April 13, 2005 |
Current U.S.
Class: |
2/195.8 |
Current CPC
Class: |
A42C 1/00 20130101; A42B
1/06 20130101; A42B 1/22 20130101 |
Class at
Publication: |
002/195.8 |
International
Class: |
A42B 3/22 20060101
A42B003/22 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 17, 2005 |
KR |
10-2005-0022258 |
Claims
1. A cap comprising: a crown portion formed by combining at least
two stretchable fabric pieces, and each fabric piece is provided
with an incision portion, and each incision portion is partially
overlapped with itself by a sewing thread in such a manner that the
sewing thread is not viewed from the outside; wherein the fabric
pieces are made of a run-proof material for preventing a run at a
seam portion of the fabric pieces, the seam portion being directly
contactable to a head of a wearer, and the run proof material is of
a single weft material including 94% to 98% of polyester and 2% to
6% of polyurethane.
2. (canceled)
3. (canceled)
4. A cap comprising: a crown portion formed of at least one
stretchable fabric piece, wherein the at least one fabric piece is
made of a run-proof material for preventing a run at a seam portion
of the at least one fabric piece, the seam portion being directly
contactable to a head of a wearer, the at least one fabric piece is
a knitted fabric of a single weft material, and the knitted fabric
is of a single weft material including 94% to 98% of polyester and
6% to 2% of polyurethane.
5. A method for manufacturing a cap, comprising: forming a
plurality of fabric pieces for a crown portion by cutting; forming
incision portions in the fabric pieces after the forming of the
plurality of the fabric pieces, the incision portions being formed
along central directions in partial regions of the fabric pieces;
combining the fabric pieces with a sewing thread in such a manner
that the sewing thread is not viewed from the outside; and
combining a visor portion with the crown portion, wherein the
fabric pieces are of a single weft material including 94% to 98% of
Polvester and 2% to 6% of polyurethane.
6. The method of claim 5, further comprising, after the forming of
the incision portions, overlapping the incision portions on
themselves and combining the overlapped portions by a sewing thread
in such a manner that the sewing thread is not viewed from the
outside.
Description
BACKGROUND OF THE INVENTION
[0001] (a) Field of the Invention
[0002] The present invention relates to a cap and a manufacturing
method thereof, and more particularly, to a highly elastic and
easily wearable cap and a manufacturing method thereof having a
simplified manufacturing process so as to provide enhanced
productivity.
[0003] (b) Description of the Related Art
[0004] A typical cap includes a crown portion of a hemispherical
shape to cover a head portion and a visor portion combined with the
crown portion to block sunlight.
[0005] The cap is usually manufactured by the following process.
That is, a cloth is firstly cut into a plurality of fabric pieces
for a crown portion. Then, the fabric pieces are disposed to
partially overlap, and are then connected by a presewing. A seam
portion formed by the presewing is cut at a margin of about 5 mm,
and an end of the seam portion is wrapped by, and stitched together
with, a strip of a predetermined width such that a run may be
prevented there. A run may also be prevented by an overlock with
threads.
[0006] Such a process to form a crown portion is complicated, and
accordingly, productivity of a cap is deteriorated. Moreover,
according to such a manufacturing method of a cap, even if the
fabric pieces forming the crown portion originally have sufficient
elasticity, elasticity of the crown portion is substantially
deteriorated because of sewing at various positions.
[0007] The elasticity of a cap may be further deteriorated for
another reason, for example, by a run preventing structure (a
wrapping with a cloth or an overlock) at the seam of the fabric
pieces of the crown portion. Such a run preventing structure of the
seam of the fabric pieces of the crown portion also deteriorates
tightness of the cap when worn by a wearer.
[0008] The information disclosed in this Background of the
Invention section is only for enhancement of understanding of the
background of the invention, and therefore, unless explicitly
described to the contrary, it should not be taken as an
acknowledgement or any form of suggestion that this information
forms the prior art that is already known in this country to a
person of ordinary skill in the art.
SUMMARY OF THE INVENTION
[0009] The present invention has been made in an effort to provide
a cap and a manufacturing method thereof having advantages of an
enhanced productivity due to a simplified manufacturing process and
an enhanced commercial grade due to preservation of sufficient
elasticity of an original fabric while forming a crown portion.
[0010] In addition, the present invention has been made in an
effort to provide a cap and a manufacturing method thereof having
advantages of reduction of required parts and simplification of a
manufacturing process by preserving sufficient elasticity of a
crown portion without employing an stretchable band to an inside of
the crown portion.
[0011] An exemplary cap according to an embodiment of the present
invention includes a crown portion formed by overlapping of at
least one stretchable fabric piece, wherein the at least one fabric
piece is made of a run-proof material for preventing a run at a
seam portion of the at least one fabric piece, the seam portion
being directly contactable to a head of a wearer.
[0012] The at least one fabric piece is provided with an incision
portion, and it preserves its shape by combining the incision
portion in a partially overlapped manner.
[0013] Another exemplary cap according to an embodiment of the
present invention includes a first fabric piece, a second fabric
piece, a crown portion, and a visor portion. The first fabric piece
has a plurality of incision portions formed along a central
direction in a partial region of the first fabric piece. The second
fabric piece is combinable with the first fabric piece, and it has
a plurality of incision portions formed along the central direction
in a partial region of the second fabric piece. The crown portion
is formed by partially overlapping the first and second fabric
pieces and by partially overlapping the incision portions. The
visor portion is combined with the crown portion, and it blocks
sunlight.
[0014] An exemplary method for manufacturing a cap according to an
embodiment of the present invention includes: forming a plurality
of fabric pieces for a crown portion by cutting; forming incision
portions to the fabric pieces after the forming of the plurality of
the fabric pieces, wherein the incision portions are formed along
central directions in partial regions of the fabric pieces;
combining the fabric pieces by partially overlapping the fabric
pieces after the forming of the incision portions, and combining a
visor portion with the crown portion.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a perspective view of a cap according to an
embodiment of the present invention.
[0016] FIG. 2 illustrates an underneath view of FIG. 1.
[0017] FIG. 3 is a sectional view of FIG. 2 along the line A-A.
[0018] FIG. 4 is a flowchart illustrating a method for
manufacturing a cap according to an embodiment of the present
invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0019] Hereinafter, an embodiment of the present invention is
described in detail with reference to the drawings.
[0020] FIG. 1 is a perspective view of a cap according to an
embodiment of the present invention, and FIG. 2 illustrates the
underneath view of the cap shown in FIG. 1.
[0021] The cap includes a crown portion 1 for covering a head of a
wearer. The cap also includes a visor portion 3 combined with the
crown portion 1.
[0022] The crown portion 1 includes two fabric pieces 5 and 7.
Cloth, which is stretchable in the directions of circumference and
height of a head of a wearer (refer to the directions shown in
solid arrows), may be used as a material for the fabric pieces.
[0023] Firstly, as an embodiment of the present invention, a cap
manufactured from the two fabric pieces 5 and 7, and a
manufacturing method thereof, are described in detail.
[0024] A plurality of incision portions 5a and 5b are formed in the
first fabric piece 5 in a central direction (i.e., toward a center
of the crown portion of a generally circular shape). Similarly, a
plurality of incision portions 7a and 7b are formed in the second
fabric piece 7 in a central direction. The first and second fabric
pieces 5 and 7 are of the same shape such that a combination of the
first and second fabric pieces 5 and 7 may form a hemispherical
shape.
[0025] When combined, the incision portions 5a, 5b, 7a, and 7b form
a dome shape of the crown portion 1 for comfortably covering a head
of a wearer.
[0026] FIG. 3 is a sectional view of FIG. 2 along the line A-A, and
it illustrates a combination of first and second fabric pieces 5
and 7. The first and second fabric pieces 5 and 7 are disposed to
partially overlap each other, and then the overlapped portion is
stitched by a sewing thread 9.
[0027] Subsequently, the incision portions 5a, 5b, 7a, and 7b are
disposed to partially overlap, and are then stitched by the sewing
thread 9. That is, the incision portions 5a, 5b, 7a, and 7b
provided at the first and second fabric pieces 5 and 7 are combined
by the sewing thread 9, and the combination of the first and second
fabric pieces 5 and 7 forms the crown portion 1 for covering a head
of a wearer.
[0028] Although an embodiment of the present invention has been
exemplarily described in connection with the case that the crown
portion 1 is made of two fabric pieces, the present invention is
not limited thereto. The number of fabric pieces may be variously
changed.
[0029] The first and second fabric pieces 5 and 7 are preferably
formed as a knitted fabric that includes polyurethane and has a
single weft structure. However, the fabric pieces are not limited
to the above-mentioned examples of the present invention. To the
contrary, any material (textile fabric, cloths, and so forth) that
has high elasticity and shows run-proof characteristics at an
incision portion (refer to the seam portion 10 of FIG. 3) may be
used for such fabric pieces.
[0030] In addition, according to an embodiment of the present
invention, a run-proof material is used for preventing a run at the
seam portion, and it does not necessitate a separate strip to be
applied to the seam portion. Therefore, deterioration of
stretchability of a cap due to the strip may be resolved, and a cap
according to an embodiment of the present invention shows an
enhanced stretchability.
[0031] On the other hand, according to an embodiment of the present
invention, seam portions are concentrated at a portion above a head
of a wearer. Therefore, a seam portion is not formed at a position
contacting a forehead or a circumference of a head of a wearer, and
accordingly, comfort may be enhanced. In addition, an overall
increased elasticity may enhance tightness of the cap.
[0032] In addition, it is preferable that the knitted fabric is of
single weft material including 94% to 98% of polyester and 6% to 2%
of polyurethane. Such a range of materials has been chosen to
promise sufficient warmth retaining property and a sufficient
stretchability.
[0033] Such a cap according to an embodiment of the present
invention may be manufactured in the following exemplary
method.
[0034] Firstly at step S1, the first and second fabric pieces 5 and
7 for forming the crown portion 1 are prepared by cutting an
original fabric.
[0035] Subsequently at step S3, a plurality of incision portions
5a, 5b, 7a, and 7b are formed in the first and second fabric pieces
5 and 7 in centralized directions such that a dome shape may be
formed when combining the first and second fabric pieces 5 and 7.
The incision portions 5a, 5b, 7a, and 7b may be formed by a
conventional cutting device.
[0036] Preferably, the incision portions 5a, 5b, 7a, and 7b are
formed in partial regions of the first and second fabric pieces 5
and 7, such that the crown portion 1 may easily form a dome
shape.
[0037] Subsequently at step S5, the incision portions 5a, 5b, 7a,
and 7b are arranged to overlap, and then are combined by the sewing
thread 9. In addition, the first and second fabric pieces 5 and 7
are also arranged to overlap, and then combined by the sewing
thread 9. Although different sewing threads may be used for
combining of the fabric pieces 5 and 7 and for combining of the
incision portions 5a, 5b, 7a, and 7b, they are referred to herein
with the same reference number for the purpose of better
comprehension of the spirit of the present invention.
[0038] After the crown portion 1 is formed in the dome shape, a
visor portion 3 is combined with the crown portion 1 by, e.g.,
stitching, at step S7.
[0039] According to a cap of an embodiment of the present
invention, a process of attaching a strip to a seam portion
combining the first and second fabric pieces 5 and 7 as well as to
a seam portion (refer to the reference number 10 in FIG. 3)
combining the incision portions 5a, 5b, 7a, and 7b is not
required.
[0040] In particular, according to an embodiment of the present
invention, the seam portion of the first and second fabric pieces 5
and 7 and the seam portion of the incision portions 5a, 5b, 7a, and
7b may become spread and contactable to a head of a wearer.
[0041] Such a cap may be manufactured by a simple process, and
accordingly, manufacturing cost may be reduced. In addition, a
crown portion may be immediately formed by presewing with a sewing
thread, and accordingly, an stretchability of a crown portion may
be preserved without deterioration.
[0042] According to an embodiment of the present invention, a crown
portion may be completed by simply sewing stretchable fabric
pieces, and therefore, the manufacturing process is simplified such
that productivity may be enhanced. Moreover, a commercial grade may
be enhanced, since an stretchability of a cap may be preserved.
[0043] While this invention has been described in connection with
what is presently considered to be practical exemplary embodiments,
it is to be understood that the invention is not limited to the
disclosed embodiments, but, on the contrary, is intended to cover
various modifications and equivalent arrangements included within
the spirit and scope of the appended claims.
* * * * *