Cap and method for forming the same

Abstract

A cap and a method for forming the same are provided. An integrally formed outer layer of fabric and an integrally formed moldable layer are adhesively bonded together to form a moldable front panel. A curved front side of the front panel is then formed by a mold. After that, the front panel and a plurality of side panels are connected to form a crown, and a peak is subsequently connected to the front panel of the crown to form the cap. Once the curved front side of the front panel is formed by heating and pressure application through the mold, the integrally formed moldable layer keeps the front panel in shape, so there is no need to support the outer layer of fabric and curve the front panel with two pieces of buckram that are stitched together, as is conventionally required.

What is claimed is: 
     
         1 . A method for forming a cap, comprising the steps of:
 adhesively bonding together an integrally formed outer layer of fabric and an integrally formed moldable layer to form a moldable front panel;   forming a curved front side of the front panel by a mold;   connecting the front panel and a plurality of side panels to form a crown; and   connecting a peak to the front panel of the crown to form the cap.   
     
     
         2 . The method for forming a cap as claimed in  claim 1 , wherein the front panel has a layer of buckram adhesively bonded to the moldable layer. 
     
     
         3 . The method for forming a cap as claimed in  claim 1 , wherein the moldable layer is made of wool, and the mold works at a molding temperature between 165° C. and 195° C. 
     
     
         4 . The method for forming a cap as claimed in  claim 1 , wherein the moldable layer is made of an ethylene-vinyl acetate (EVA) material, and the mold works at a molding temperature between 185° C. and 215° C. 
     
     
         5 . The method for forming a cap as claimed in  claim 1 , wherein the moldable layer is made of polypropylene (PP), and the mold works at a molding temperature between 100° C. and 120° C. 
     
     
         6 . The method for forming a cap as claimed in  claim 1 , wherein the crown is formed by connecting the front panel and four side panels. 
     
     
         7 . The method for forming a cap as claimed in  claim 1 , wherein the outer layer of fabric of the front panel is integrally formed with the side panels. 
     
     
         8 . The method for forming a cap as claimed in  claim 7 , wherein the integrally formed moldable layer is adhesively bonded to the front panel and the side panels. 
     
     
         9 . A cap, comprising:
 a crown having a front panel and a plurality of side panels, wherein the front panel and the side panels are connected, the front panel has an integrally formed outer layer of fabric and an integrally formed moldable layer adhesively bonded to the outer layer of fabric, and the front panel has a curved front side formed by a mold; and   a peak connected to the front panel of the crown.   
     
     
         10 . The cap of  claim 9 , wherein the front panel has a layer of buckram adhesively bonded to the moldable layer. 
     
     
         11 . The cap of  claim 9 , wherein the moldable layer is made of one of wool, an ethylene-vinyl acetate (EVA) material, and polypropylene (PP). 
     
     
         12 . The cap of  claim 9 , wherein the crown is formed by connecting the front panel and four side panels. 
     
     
         13 . The cap of  claim 9 , wherein the outer layer of fabric of the front panel is integrally formed with the side panels. 
     
     
         14 . The cap of  claim 13 , wherein the integrally formed moldable layer is adhesively bonded to the front panel and the side panels.