Cap Crown Panel Lining Design for Thin Seams
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Solution Overview
Problem
Traditional cap manufacturing methods result in thick and stiff seam portions due to the use of thick chemical fiber linings, leading to discomfort for wearers and issues with embroidery productivity and quality.
Innovation Solution
The cap design includes crown panels with lining and outer panels of different sizes, connected by first sewing with the outer panels spaced apart from the edge, and covered with a seam cover tape to create a thin seam portion, improving comfort and reducing embroidery machine breakages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If thick chemical fiber lining is used to maintain cap shape, then shape stability is improved, but seam portion thickness increases causing discomfort
Solution Approach 1:
The invention divides the lining structure into separate panels that are strategically positioned. The lining panels are placed only in specific regions (front, back, and sides) rather than covering the entire crown, allowing the crown to maintain shape stability where needed while reducing thickness and improving comfort in seam areas where the lining is absent or minimized.
Solution Approach 2:
The invention applies lining material selectively in specific locations rather than uniformly across the entire crown. The lining panels are positioned to provide shape maintenance in critical areas while being excluded from or minimized in seam portions, creating local variations in structure that simultaneously achieve shape stability and wearing comfort.
2Strength
If thick seam portions are formed by traditional sewing method, then structural integrity is improved, but embroidery quality deteriorates due to needle and thread breakage
Solution Approach 1:
The invention extracts or removes the lining material from the seam portions, creating thin or absent seams in the areas where embroidery will be applied. This extraction eliminates the thickness and rigidity problems that cause needle and thread breakage during embroidery, while the lining panels in other areas maintain overall structural integrity.
Solution Approach 2:
The invention changes the dimensional structure by creating a stepped or layered configuration where the lining panels are positioned at different levels or distances from the outer surface. This dimensional arrangement allows the seam portions to be thin for embroidery compatibility while maintaining structural support through the spatial distribution of lining material.
3Shape
If traditional sewing method with tape is used to connect panels, then aesthetic appearance is improved, but productivity decreases due to increased complexity
Solution Approach 1:
The invention merges the functions of multiple components into a simplified structure. By eliminating the separate tape component and reducing the number of sewing operations, the invention combines shape maintenance and panel connection functions into a more integrated and streamlined construction process, improving manufacturing efficiency.
Solution Approach 2:
The invention inverts the traditional approach by removing excess material and steps rather than adding them. Instead of adding tape and multiple sewing layers to achieve aesthetic appearance, the invention achieves clean seams and visual appeal through minimal construction, reversing the conventional logic of adding complexity to improve appearance.
Data Source
AI summary
A cap according to an embodiment of the present disclosure includes a crown part manufactured by connecting a plurality of crown panels, a visor part attached to a lower end of the crown part, and a sweatband part attached to an inner lower end of the crown part, in which two front panels, among the plurality of crown panels, each include a lining panel configured to define an inner side of the crown part, and an outer panel configured to define an outer side of the crown part and be cut out with an area larger than the lining panel, and in which at least two crown panels, which are adjacent to each other among the plurality of crown panels, are connected to each other by first sewing.