Hats, Caps, and Methods for Manufacturing the Same

Abstract

Disclosed are methods for manufacturing at least portions of hats and caps, as well as at least portions of hats and caps manufactured by the disclosed methods. In examples, provided are methods for fabricating a biretta, which can include (1) forming, using a hat block, a plastic biretta hat foundation from a heat-activated low-melt polyester fiber, (2) forming, using a horn block, at least one plastic biretta horn from the same type of heat-activated low-melt polyester fiber, and (3) fastening a plastic biretta horn along an exterior ridge of the plastic biretta hat foundation. An orifice can be formed in a peak of the plastic biretta hat foundation. At least a part of the plastic biretta hat foundation can be covered with a fabric cover. A twist rope or a pom fastener can be passed through the orifice to secure the twist rope or a pom to the plastic biretta hat foundation.

What is claimed is: 
     
         1 . A biretta, comprising:
 a plastic biretta hat foundation having a first exterior ridge, wherein the plastic biretta hat foundation is formed from plastic; and   a first horn foundation having a first base portion fastened along the first exterior ridge of the plastic biretta hat foundation, wherein the first horn foundation is formed from the same composition of plastic as the plastic biretta hat foundation.   
     
     
         2 . The biretta of  claim 1 , further comprising a second horn foundation having a second base portion fastened along a second exterior ridge of the plastic biretta hat foundation, wherein the second horn foundation comprises the same composition of plastic as the plastic biretta hat foundation. 
     
     
         3 . The biretta of  claim 2 , further comprising a third horn foundation having a third base portion fastened along a third exterior ridge of the plastic biretta hat foundation, wherein the third horn foundation comprises the same composition of plastic as the plastic biretta hat foundation. 
     
     
         4 . The biretta of  claim 1 , wherein the plastic is a thermoplastic. 
     
     
         5 . The biretta of  claim 4 , wherein the plastic is a non-woven heat-activated polyester fiber material that has been activated. 
     
     
         6 . The biretta of  claim 5 , wherein the activated polyester fiber material has an activation temperature between 150 degrees Fahrenheit and 265 degrees Fahrenheit, inclusive. 
     
     
         7 . The biretta of  claim 1 , wherein the plastic is a thermosetting plastic. 
     
     
         8 . The biretta of  claim 1 , further comprising a fabric cover fastened to the plastic biretta hat foundation and covering at least a portion of the exterior of the plastic biretta hat foundation. 
     
     
         9 . The biretta of  claim 1 , wherein the plastic biretta hat foundation defines an orifice. 
     
     
         10 . The biretta of  claim 9 , wherein the plastic biretta hat foundation defines the orifice at a peak of the plastic biretta hat foundation. 
     
     
         11 . The biretta of  claim 9 , further comprising a portion of a twist rope passing through the orifice. 
     
     
         12 . The biretta of  claim 9 , further comprising a pom having a pom fastener, wherein a portion of the pom fastener passes through the orifice. 
     
     
         13 . A method for fabricating a biretta, comprising:
 forming, using a hat block, a plastic biretta hat foundation from a non-woven heat-activated low-melt polyester fiber;   forming, using a horn block, at least one plastic biretta horn from the same composition of non-woven heat-activated low-melt polyester fiber; and   fastening the at least one plastic biretta horn along a first exterior ridge of the plastic biretta hat foundation.   
     
     
         14 . The method of  claim 13 , wherein the forming the plastic biretta hat foundation further comprises applying an unactivated sheet of the non-woven heat-activated low-melt polyester fiber to the hat block to form the unactivated sheet of the non-woven heat-activated low-melt polyester fiber in a shape of the plastic biretta hat foundation. 
     
     
         15 . The method of  claim 14 , wherein the forming the plastic biretta hat foundation further comprises activating the non-woven heat-activated low-melt polyester fiber of the plastic biretta hat foundation by heating the non-woven heat-activated low-melt polyester fiber of the plastic biretta hat foundation to an activation temperature between 150 degrees Fahrenheit and 265 degrees Fahrenheit. 
     
     
         16 . The method of  claim 13 , wherein the forming the plastic biretta horn further comprises applying an unactivated sheet of the non-woven heat-activated low-melt polyester fiber to the horn block to form the unactivated sheet of the non-woven heat-activated low-melt polyester fiber in a shape of the plastic biretta horn. 
     
     
         17 . The method of  claim 16 , wherein the forming the plastic biretta horn further comprises activating the non-woven heat-activated low-melt polyester fiber of the plastic biretta horn by heating the non-woven heat-activated low-melt polyester fiber of the plastic biretta horn to an activation temperature between 150 degrees Fahrenheit and 265 degrees Fahrenheit. 
     
     
         18 . The method of  claim 13 , further comprising forming an orifice in the plastic biretta hat foundation. 
     
     
         19 . The method of  claim 18 , wherein the orifice is formed at a peak of the plastic biretta hat foundation. 
     
     
         20 . The method of  claim 13 , further comprising fastening a fabric cover to the plastic biretta hat foundation such that the fabric cover covers at least a portion of an exterior of the plastic biretta hat foundation.