# US 2019/0166941 A1 · Cap and method of manufacturing a cap > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2019/0166941 A1 - Document ID: US20190166941A1 - Status: Published application - Kind: A1 - Application number: 16/270,868 - Filed: 2019-02-08 - Published: 2019-06-06 - Earliest claimed: 2019-02-08 - Assignees: Shanghai Pacific Hat Manufacturing Company, LTD - Applicants: Shanghai Pacific Hat Manufacturing Company, LTD - Inventors: Zhen MAO - Web page: https://patentgrep.com/patent/US20190166941A1 ## CPC - A42B 1/22: adjustable in size {; Form-fitting or self adjusting head coverings; Devices for reducing hat size} - A42B 1/0182: Peaks or visors - A42B 1/02: Hats; Stiff caps - A42C 1/02: Making hat-bats; Bat-forming machines; Conical bat machines; Bat-forming tools - A42C 1/04: Blocking; Pressing; Steaming; Stretching - A42C 1/06: Manipulation of hat-brims - A42C 1/08: Hat-finishing, e.g. polishing, ironing, smoothing, brushing, impregnating, stiffening, decorating - A42B: HATS; HEAD COVERINGS (headbands A41D20/00; head-scarves A41D23/00) - A42C: MANUFACTURING OR TRIMMING HEAD COVERINGS, e.g. HATS ## Abstract A baseball cap and method of assembling thereof is provided. The cap includes a single-panel crown that is formed from a single sheet or single piece of stretchable fabric, such as using heat pressing techniques. The single-panel crown has a hemispherical shape. The cap further includes a support layer, such as made from buckram, which is attached to an interior, front portion of the single-panel crown, and a visor and an elastic band which are attached to the single-panel crown. ## Claims ### Claim 1 A method of assembling a cap comprising: forming a single-panel crown for a cap from a single sheet or single piece of stretchable fabric; attaching a support layer to an interior portion of the single-panel crown; and attaching a visor and an elastic band to the single-panel crown with the attached support layer. ### Claim 2 (depends on 1) The method according to claim 1, wherein the forming a single-panel crown comprises: heating and stretching the single sheet or single piece of stretchable fabric to form a hemispherical shape on a portion of the stretchable fabric. ### Claim 3 (depends on 2) The method according to claim 2, wherein the forming a single-panel crown further comprises: cutting any extra edge portion or portions of the stretchable fabric that extend from or beyond the hemispherical shaped portion in order to form the single-panel crown for the cap; ### Claim 4 (depends on 2) The method according to claim 2, wherein the heating and stretching comprises: applying heat to one or both sides of the stretchable fabric; and as heat is applied, applying a pressing force with a hemispherical shaped fabric mold to stretch the portion of the stretchable fabric into the hemispherical shape. ### Claim 5 (depends on 1) The method according to claim 1, wherein the stretchable fabric comprises a woven or non-woven material. ### Claim 6 (depends on 5) The method according to claim 5, wherein the stretchable fabric includes 2% to 5% spandex. ### Claim 7 (depends on 1) The method according to claim 1, wherein the support layer comprises buckram, the attaching a support layer comprising: applying an adhesive to a surface of the buckram or an interior, front portion of the single-panel crown; and pressing the buckram against the interior, front portion of the single-panel crown so that the adhesive bonds the buckram to the interior, front portion of the single-panel crown. ### Claim 8 (depends on 7) The method according to claim 7, further comprising: applying bonding tape over one or more seams that are formed between an edge of the buckram and an interior surface of the single-panel crown, each of the one or more seams extending radially from an interior, central portion to a bottom edge of the single-panel crown, the bonding tape covering the one or more seams and further connecting the buckram to the single-panel crown. ### Claim 9 (depends on 1) The method according to claim 1, wherein the attaching a visor and an elastic band comprises stitching the visor and the elastic band to the single-panel crown, the elastic band attached around an interior, bottom edge of the single-panel crown. ### Claim 10 (depends on 1) The method of claim 1, wherein the cap is a baseball cap, and the elastic band is a sweatband. ### Claim 11 (depends on 1) The method of claim 1, wherein the single sheet or single piece of stretchable fabric comprises a fabric blank of the stretchable fabric, wherein the forming a single-panel crown comprises: heating and stretching the fabric blank of the stretchable fabric to form a single-panel crown having a hemispherical shape. ### Claim 12 Headwear comprising a cap that includes: a single-panel crown formed from a single sheet or single piece of stretchable fabric and having a hemispherical shape; a support layer attached to an interior portion of the single-panel crown; and a visor and an elastic band that are attached to the single-panel crown. ### Claim 13 (depends on 12) The headwear according to claim 12, wherein the stretchable fabric comprises a woven or non-woven material. ### Claim 14 (depends on 13) The headwear according to claim 13, wherein the stretchable fabric includes 2% to 5% spandex. ### Claim 15 (depends on 12) The headwear according to claim 12, wherein the support layer comprises buckram, which is heat bonded to an interior, front portion of the single-panel crown using an adhesive. ### Claim 16 (depends on 15) The headwear according to claim 15, further comprising: bonding tape applied over one or more seams that are formed between an edge of the buckram and an interior surface of the single-panel crown, each of the one or more seams extending radially from an interior, central portion to a bottom edge of the single-panel crown, the bonding tape covering the one or more seams and further connecting the buckram to the single-panel crown. ### Claim 17 (depends on 12) The headwear according to claim 12, wherein the visor and the elastic band are stitched to the single-panel crown, the elastic band being attached around an interior, bottom edge of the single-panel crown. ### Claim 18 (depends on 12) The headwear according to claim 12, wherein the cap is a baseball cap, and the elastic band is a sweatband.