FRONT PANEL OF A HAT AND A HAT USING THE SAME

Description

BACKGROUND OF THE DISCLOSURE

Field of the Disclosure

The present disclosure relates to the front panel of a hat and a method for manufacturing a hat using the same.

Description of the Related Art

The early baseball hats, in which a round cap and a brim are connected to block glare caused by sunlight, have evolved repeatedly to include a protective function to protect the head and face from the external environment, and have now evolved into a type of outdoor clothing that can express the uniqueness of fashion in various ways.

The current six-panel baseball hats are made by joining six panels, two on the front, two on the sides, and two on the back, placing a thin fabric on the boundary between panels, and then connecting the panels using double-needle sewing to create a three-dimensional cap that fits the human head.

The cap is then connected to a wide, crescent-shaped brim, completing a typical hat that casts shade on the face.

If the fabric used during such a process is thin or includes spandex, quality issues may arise, such as the sewing thread not being properly sewn, creases occurring between vertically curved sewing lines, or the cap being easily wrinkled.

In order to prevent this, bonding a buckram capable of complementing the shortcomings of the fabric may improve the above problems and greatly help maintain the appearance.

A first background art is shown in FIG. 7A, in which, since a panel and a buckram should be additionally bonded, the connection portion between panels becomes thicker, a connection sewing line protrudes to cause an appearance problem, and the corresponding portion may cause uncomfortableness when a hat is worn.

In addition, a quality problem such as design breakage may occur during embroidery and printing operations on the corresponding part.

This leads to poor brand logo and design on the front panel (front surface) of a hat, which in turn leads to a decline in the manufacturer's reliability, poor quality, and poor sales.

In order to improve the above problems, various non-bonding methods have been attempted, but, by confirming that the current fashion market trends toward hats manufactured through bonding methods, the present disclosure has been made to solve the problems through a bonding method.

A second background art is shown in FIG. 7B and FIG. 7C, and is disclosed in Korean Patent Registration No. 10-1848290 (2018.04.12) filed and registered in the name of the present applicant. The second background art provides a method for manufacturing a front portion of a crown, including: sewing panels together to create a front panel of a hat, and positioning and sewing a third fabric section coupling band inside the front panel to prevent any crease from being formed in a sewn coupling portion;

• • positioning a second fabric section inside a third fabric section in order to maintain a partial shape of a crown, and preparing two fabric sections with the same shape as a front left fabric section and a front right fabric section of the third fabric section;
  • preparing the second fabric section by sewing the two fabric sections together;
  • positioning and sewing a second fabric section coupling band inside the second fabric section to prevent any crease from being formed 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 circumferential edges of the second fabric section and the third fabric section, thereby completing a part of the crown; and
  • positioning the part of the crown in a heating device that applies heat and pressure, thereby positioning the second fabric section and the third fabric section more closely to each other.

The second background art requires that first sewing be done twice, double-needle sewing also be done twice, a process of sewing the entire second and third fabric sections be performed, and so on. Such sewing is a very difficult technology to use because the sewing serves as a considerable thickness when connecting a next fabric section.

In addition, there is a disadvantage in that, due to the presence of the fabric section coupling bands disposed on the sewn coupling portions of the second and third fabric sections, the outer and inner layers of the hat are likely to become separated from each other due to frequent moisture penetration over time, making it difficult to maintain the original shape of the hat.

Therefore, there is no choice but to select a technology that maintains the shape of a hat through a process in which the buckram and the panel of a panel buckram should be first thermally bonded.

The present disclosure has been invented under this background.

CITATION LIST

Patent Literature

• • Patent Literature 1: Korean Patent Registration Number 10-1848290 (2018.04.12)
  • Patent Literature 2: Korean Patent Registration Number 10-1588756 (2016.01.26)
  • Patent Literature 3: Korean Patent Registration Number 10-1302399 (2013.09.02)

SUMMARY OF THE DISCLOSURE

Technical Problem

A first problem to be solved by the present disclosure is to solve the shortcomings of the background arts in that a sewing line portion is flat on the front portion of a hat so that a logo is evenly printed without a protrusion during logo printing and thus a pattern is not distorted and the quality of a logo work is significantly improved.

A second problem to be solved by the present disclosure is to solve a problem that a sewing needle breaks in the sewing part of the front panel of a hat while doing a logo work by embroidery.

A third problem to be solved by the present disclosure is to solve a problem that it is necessary to embroider at a slow speed because the load index of a sewing needle is similar around a sewing part and at the other parts during embroidery, thereby increasing productivity by enabling embroidery at a fast speed.

A fourth problem to be solved by the present disclosure is to solve the problems of the background art by improving the convenience of a user who complains of discomfort on the forehead corresponding to the front portion of a hat through ensuring that a part that comes into contact with the head of the user wearing the hat is in even contact.

A fifth problem to be solved by the present disclosure is to solve the problems of the background art by configuring the front panel of a hat to maintain and strengthen the shape stability for a long time, thereby providing the effects of a stable shape and an attractive appearance for the front portion of the hat.

Solution to Problem

In order to solve the above problems, the present disclosure has the following configuration.

A hat front panel forming a front portion of a hat and configured with a first panel buckram and a second panel buckram is provided.

Each of the first panel buckram and the second panel buckram is configured by attaching a buckram and a panel by thermal bonding.

The first panel buckram is configured by attaching a first buckram and a first panel.

The second panel buckram is configured by attaching a second buckram and a second panel.

When the first panel buckram and the second panel buckram are combined with each other by first sewing, each seam allowance is configured by removing a buckram, so that, when the first panel buckram and the second panel buckram are sewn to each other, a first sewing line, which is a sewing connection line formed on a sewing surface, is configured so that there is no loosening and protrusion.

In order to cover seam allowances around the first sewing line on a rear surface of the hat front panel, double-needle sewing as second sewing is performed using a sewing finish tape.

The hat front panel is configured to maintain a flat surface on left and right sides of the first sewing line so as to eliminate a defect rate of embroidery and printing works on the hat front panel.

The first buckram and the first panel may be configured to be thermally bonded to each other in a thermal bonding device, and the second buckram and the second panel may also be configured to be thermally bonded to each other in the thermal bonding device.

A melting tape may be configured inside together with the sewing finish tape, double-needle sewing may be performed, and an area of the melting tape may be thermally compressed in a thermocompression bonding device to couple the first buckram and the second buckram to each other due to melting of the melting tape, so that shape stability is enhanced and an attractive appearance is provided.

A hat is manufactured using the hat front panel.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a view showing the construction of a panel;

FIG. 1B is a view showing the construction of a buckram;

FIG. 2A is a view showing the construction of the panel and the buckram in a state in which the buckram is partially removed so as not to overlap a portion of the panel serving as a seam allowance;

FIG. 2B and FIG. 2C are views showing that the panel and the buckram are moved so as to be thermally bonded on a thermal bonding device;

FIG. 2D is a view showing a panel buckram in which the panel and the buckram are thermally bonded;

FIG. 3A and FIG. 3B are views showing that panels with buckrams partially removed are first sewn with each other in a sewing machine;

FIG. 4A is a view showing that a double-needle sewing is performed by placing a sewing finish tape and a melting tape together on the rear surface of the front panel of a hat;

FIG. 4B is a view showing the rear surface of the front panel of the hat after the double-needle sewing of FIG. 4A is performed;

FIG. 4C is a view showing the front surface of the front panel of the hat after the double-needle sewing of FIG. 4A is performed;

FIG. 5A and FIG. 5B are views showing a state in which a thermocompression bonding device is disposed to apply heat to the melting tape on the rear surface of the front panel of the hat so as the melt the melting tape;

FIG. 5C is a view showing the front panel of the hat after being thermally bonded in the thermocompression bonding device;

FIG. 6A to FIG. 6C are views showing a hat to which the front panel of the hat of FIG. 5C is applied; and

FIG. 7A to FIG. 7C are views showing the background art.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

In order to invent the present disclosure, the following trial and error processes were experimented.

Primarily, after bonding buckrams, seam allowances that protrude when sewn by double-needle sewing in a panel state were ground with a grinder.

By doing this, it was possible to grind a thick surface, but a ground surface is not even. In addition, as a panel viewed outside was also ground, causing a thread to come loose, it was determined that unsuitableness for sewing and a finishing work was caused.

A second method is pressing.

After bonding, when pressing through a pressing operation in which high-temperature heat and strong pressure are applied to seam allowances in a panel state, a cut material itself was burned, deformed and cured by a thermal phenomenon, and thus, it was determined that unsuitableness for sewing and finishing was caused.

By the above trials and errors, the present disclosure has implemented the following embodiments.

A first embodiment is a configuration of partially removing buckrams.

When cutting buckrams, portions of the buckrams corresponding to protruding sewing portions were removed and then the buckrams were bonded to panels, thereby configuring seam allowances in a state in which the buckrams are not bonded thereto, thereby improving the appearance problem (protrusion) during production of a hat.

A part where the buckram to be bonded is partially removed is thinner than a part where the buckram is bonded, which is good for a logo work such as embroidery and the like, but a part around a double-needle sewing line connecting the front panels of the hat has some disadvantages in that it does not stand enough strength and wrinkles appear over time.

In a second embodiment, a melting tape is attached to a double-needle sewing portion.

After first sewing is performed to couple a first panel buckram 310 and a second panel buckram 320 to each other after partially removing buckrams at seam allowances, double-needle sewing is performed around a first sewing line.

After the seam allowances of the first panel buckram 310 and the second panel buckram 320 are sewn in a state in which buckrams are not bonded thereto, a melting tape 410 is sewn by being positioned onto a corresponding portion (a front double-needle sewing portion).

After sewing, thermal bonding is performed using a thermocompression bonding device 900 being a dedicated bonding machine, thereby improving some of the problems occurring in the first embodiment through excellent shape stability and the melting effect of the melting tape 410.

With this configuration, all other issues found in the non-bonding sewing method have been resolved.

Problems of the background arts include the phenomenon of the sewing line between panels to become loose and frayed, the phenomenon of a double-needle sewing line to protrude, the phenomenon of embroidery defects due to the protrusion of a sewing line, and the phenomenon of a double-needle sewing portion to wrinkle when performing a logo work.

Conversely, in the second embodiment of the present disclosure, the buckrams are partially removed from the seam allowances and the melting tape 410 is positioned on the seam allowances together with a sewing finish tape 420 at the time of performing double-needle sewing.

Then, after being thermally bonded using the thermocompression bonding device 900, a hat front panel 500 is externally attractive and maintains a solid appearance, thereby resolving all of the problems encountered so far when applied to a hat, and also improving durability and enabling stable workability and shape to be maintained.

The phenomenon of loosening and fraying at the sewing connection part of a six-panel baseball hat was a chronic problem that lowers the embroidery quality, but by using the melting tape 410, connection line parts are able to be stably coupled without any protruding portions.

As a result, first sewing line exposure prevention and logo work quality have been significantly improved, and the brand identity may be stably expressed while maintaining the quality without any problem with any type of fabric and sewing method.

Hereinafter, the first embodiment and the second embodiment will be described in detail with reference to the drawings.

Embodiments will be described in detail with reference to FIG. 1A to FIG. 6C as follows.

A first embodiment will be described in detail with reference to the drawings as follows.

A hat front panel 500 forms the front portion of a hat 600, and is configured with a first panel buckram 310 and a second panel buckram 320.

The hat front panel 500 is constituted by the first panel buckram 310 and the second panel buckram 320.

Each of the first panel buckram 310 and the second panel buckram 320 is configured by attaching a buckram 200 and a panel 100 by thermal bonding.

This will be described with reference to FIG. 1A and FIG. 1B as follows.

A first buckram 210 and a first panel 110 and a second buckram 220 and a second panel 120 are cut by a cutting device 150.

The first panel buckram 310 is configured by attaching the first buckram 210 and the first panel 110 by thermal bonding.

The corresponding second panel buckram 320 is configured by attaching the second buckram 220 and the second panel 120 by thermal bonding.

FIG. 2A to FIG. 2D will be described as follows.

Before performing thermal bonding, the first buckram 210 is formed to be smaller than the first panel 110, is disposed to be in a state in which a portion of the first buckram 210, being a portion corresponding to a first seam allowance 115, is removed, and is moved to a thermal bonding device 700.

The first buckram 210 and the first panel 110 that have passed through the thermal bonding device 700 are attached to each other to form the first panel buckram 310.

The corresponding second panel buckram 320 to be sewn with the first panel buckram 310 is configured by attaching the second buckram 220 and the second panel 120 by thermal bonding.

FIG. 3A and FIG. 3B will be described as follows.

When the first panel buckram 310 and the second panel buckram 320 are combined with each other by first sewing, portions of the first buckram 210 and the second buckram 220 corresponding to seam allowances are removed to form seam allowances 115 and 125.

Thus, when the first panel buckram 310 and the second panel buckram 320 are sewn to each other, a first sewing line “a,” which is a sewing connection line formed on a sewing surface, is configured so that there is no loosening and protrusion.

It is norm that a buckram is significantly thicker than a panel.

Therefore, because a portion of the buckram corresponding to a seam allowance is removed in a panel buckram, when sewing the seam allowance, the seam allowance may be formed to be thinner than other portions.

The hat front panel 500 is formed by sewing the first panel buckram 310 and the second panel buckram 320 to each other.

In the case of a hat, the hat front panel 500 should be erected upright to maintain its shape, and thus, a buckram is configured.

However, a sewn portion of the front portion of a hat, which is the center portion of the hat, becomes thicker due to the presence of the buckram, and thus, disadvantages are caused in that the crease of the sewn portion is deep and thick and a protruding shape makes the hat look rough and unattractive. The present disclosure solves the disadvantages.

With this configuration, there has been a disadvantage that an embroidery needle breaks when the embroidery is placed on the hat front panel 500, which is the front portion of the hat.

In addition, an embroidery shape could not be properly implemented.

The present disclosure is intended to prevent such disadvantages.

In addition, even when a pattern is printed on the hat front panel 500, which is the front portion of the hat, there is a disadvantage in that the pattern is not properly printed due to the deep crease of the first sewing line “a” and a protrusion around the first sewing line “a”.

In order to cover the seam allowances 115 and 125 around the first sewing line “a” on the rear surface of the hat front panel 500, double-needle sewing as second sewing is performed using a sewing finish tape 420.

The hat front panel 500 is configured to maintain a flat surface on the left and right sides of the first sewing line “a” so as to eliminate a defect rate of embroidery and printing works on the hat front panel 500.

Double-needle sewing is performed using the sewing finish tape 420 so that the first buckram 210 and the second buckram 220 are brought into direct contact with each other.

The hat front panel 500 is configured to have a more flat surface around the first sewing line “a” in a thermocompression bonding device 900.

The first buckram 210 and the second buckram 220 brought into direct contact with each other may be bonded to each other by the thermocompression bonding device 900.

However, there is a disadvantage in that the binding force between the first buckram 210 and the second buckram 220 is weakened as a time passes.

While satisfying a first requirement of ensuring that the hat front panel 500 maintains its solid shape for a long time, the sewing portion of the hat front panel 500 is made flat, so that when embroidering with a company emblem or a pattern according to a user's preference, a sewing needle does not break and embroidery may be performed smoothly and at a high speed.

However, in such an embodiment in which heat is applied from the thermocompression bonding device 900 with the first buckram 210 and the second buckram 220 brought into contact with each other, it is difficult for the first buckram 210 and the second buckram 220 to be completely bonded to each other, and even when they are bonded to each other, they are likely to be separated from each other over time.

For this reason, it is more preferable to add the configuration of a melting tape 410 of a second embodiment.

The second embodiment is as follows.

FIG. 4A to FIG. 5C will be described as follows.

The melting tape 410 is configured inside together with the sewing finish tape 420, and double-needle sewing is performed so that the first buckram 210 and the second buckram 220 are in direct contact with each other together with the melting tape 410.

After the double-needle sewing, a portion corresponding to the melting tape 410 is thermally compressed in the thermocompression bonding device 900 to completely couple the first buckram 210 and the second buckram 220 to each other due to the melting of the melting tape 410, and thus, the hat front panel 500 may firmly maintain its shape in the same manner as a buckram is present, even in a seam allowance from which a buckram is actually removed.

In the second embodiment, in addition to the effects of the first embodiment, a shape may be firmly maintained for a long period of time, and in a case where sewing is performed to connect the two first buckram 210 and second buckram 220, even when sewing is not accurately performed with buckrams brought into contact with each other, the buckrams may be sufficiently bonded to each other by the melting tape to maintain a firm shape.

Additionally, an advantage is provided in that a pattern is printed evenly during printing and thus is not distorted and appears naturally.

Furthermore, an advantage is provided in that the convenience of a user is improved through ensuring that a part that comes into contact with the head of the user wearing a hat is in even contact.

The present disclosure is configured to enhance the shape stability of the hat front panel 500 so that the shape of the front portion of a hat is stable and has an attractive appearance.

FIG. 6A to FIG. 6C show that a hat is configured using the hat front panel 500.

It is shown that two portions on the hat front part corresponds to the hat front panel 500 and a central portion in between is a double-needle sewn portion where the melting tape is configured to firmly maintain a shape by means of the thermocompression bonding device 900 while maintaining a flat surface around the first sewing line “a”.

A hat is configured using such a hat front panel 500.

Advantageous Effects of Disclosure

A first effect of the present disclosure is that a sewing line portion is flat on the front portion of a hat so that a logo is evenly printed without a protrusion during logo printing and thus a pattern is not distorted and the quality of a logo work is significantly improved.

A second effect of the present disclosure is to solve a disadvantage that a sewing needle breaks in the sewing part of the front panel of a hat while doing a logo work by embroidery.

A third effect of the present disclosure is that the load index of a sewing needle is similar around a sewing part and at the other parts during embroidery to enable embroidery at a fast speed.

A fourth effect of the present disclosure is to improve the convenience of a user through ensuring that a part that comes into contact with the head of the user wearing a hat is in even contact.

A fifth effect of the present disclosure is to configure the front panel of a hat to strengthen the shape stability, thereby providing the effects of a stable shape and an attractive appearance for the front portion of the hat.

It should be understood that the terms or words used in the specification and the appended claims should not be construed as limited to general and dictionary meanings, but should be interpreted based on the meanings and concepts corresponding to technical aspects of the present disclosure on the basis of the principle that the inventor is allowed to appropriately define the concepts of terms to describe his or her own design in the best way.

Therefore, the embodiments described in the present specification and the configurations shown in the drawings are only the most preferred embodiments of the present disclosure.

While the present disclosure has been described with respect to the specific embodiments, it will be apparent to those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the disclosure as defined in the following claims.