Moldable Cap Panel Eliminates Stitched Buckram Joints

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Solution Overview

Problem

Conventional baseball cap manufacturing methods result in defective decorations due to thick and uneven joints from stitched panels, limited decoration areas, and material constraints from using buckram, which affects the curvature and aesthetics of the cap.

Innovation Solution

An integrally formed moldable panel with a curved edge, created by bonding a fabric outer layer with a moldable layer and buckram, eliminates the need for multiple stitched buckram pieces, allowing for a single molding process that supports the fabric and maintains shape without joints, enabling flexible material choices and improved decoration quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If multiple panels are stitched together to form the crown, then the crown structure is formed, but the joints become thick and uneven causing decoration defects

Engineering Contradiction:

Improvecrown structure formationVSAvoidjoint uniformity

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The invention divides the crown into multiple panels that are stitched together, but uses bonding tape at the joints to flatten and uniform the joint areas, resolving the contradiction between forming the crown structure and maintaining joint uniformity for decoration

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Bonding tape is introduced as an intermediary element between the stitched panels to bond them together and create a flat, uniform joint surface that is suitable for subsequent decoration processes

Inventive Principle:

Principle #24Intermediary (Mediator)

2Area of stationary object

If a single panel is used at the front of the crown, then decoration area is increased, but the panel fails to provide sufficient curvature and erectness

Engineering Contradiction:

Improvedecoration areaVSAvoidcrown curvature

Core Design Contradiction:

Area of stationary objectVSShape

Solution Approach 1:

The invention uses a composite structure combining outer layer fabric with inner layer lining materials to achieve both the desired curvature and erectness of the crown while maintaining a large single panel area suitable for decoration

Inventive Principle:

Principle #40Composite materials

3Stability of the object's composition

If buckram is used to support the outer layer of fabric, then the fabric shape is maintained, but the buckram requires stitching multiple pieces together reducing reliability

Engineering Contradiction:

Improvefabric shape maintenanceVSAvoidbuckram joint integrity

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The buckram is divided into multiple pieces that are stitched together to form the complete inner layer lining, allowing the material to be applied in manageable sections while maintaining overall structural integrity and shape support

Inventive Principle:

Principle #1Segmentation

4Ease of manufacture

If panels are folded back and connected with bonding tape, then the crown joint is formed, but the joint becomes thick and uneven

Engineering Contradiction:

Improvecrown joint formationVSAvoidjoint thickness uniformity

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

Bonding tape serves as an intermediary layer that bonds the folded panels together while creating a flat, uniform joint surface, eliminating the thickness and unevenness problems associated with simple stitching or folding

Inventive Principle:

Principle #24Intermediary (Mediator)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution reduces product defects, enhances decoration quality by eliminating joint-related issues, and allows for a more aesthetically pleasing and curvaceous design without material limitations, ensuring the fabric and buckram are securely supported and evenly molded.

Implementation Method 1

heating and compressing the fabric under high pressure to mold the fabric into the desired shape

Methodology Applied

Scientific EffectHeat treatment: Heating

Implementation Method 2

heating and compressing the fabric under high pressure to mold the fabric into the desired shape

Methodology Applied

Scientific EffectPhase change: Phase Change

Data Source

PatentUS11472129B2Cap and method for forming the same

Publication Date: 2022.10.18 HWANG YA CHANG

AI summary

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 panel. A curved edge of the moldable panel is then formed by a mold. After that, the moldable panel and at least one second panel are connected to form a crown, to which a peak is subsequently connected to form the cap. Once the curved edge of the moldable panel is formed by heating and pressure application through the mold, the integrally formed moldable layer keeps the moldable panel in shape, so there is no need to support the outer layer of fabric and curve, for example, the front panel with two pieces of buckram that are stitched together, as is conventionally required.