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[ EN ]

1. Field of the Invention
THIS INVENTION relates to the manufacture of caps.
The term "caps" shall be used throughout the specification to include cap, hat, helmet, shade, visor, eye shade, or like headgear.

2. Prior Art
Conventional caps, eg., of the baseball type, usually incorporate a peak where a stiffening panel of sheet plastics or cardboard is enclosed within upper and lower fabric panels, the peak assembly being attached to a domed head covering portion, the latter generally incorporating adjustment means spaced from the peak assembly to enable one cap size to fit a range of wearer's heads.
A perspiration absorbing band may be provided within the head-covering portion, eg., to absorb perspiration from the wearer's forehead.
A known limitation with these known caps is that it is very difficult to provide advertising material on the cap peaks. Furthermore, it is difficult, if not impossible, to produce caps with peaks that have a high aesthetic appeal and which are thereby attractive to "up market" advertisers.
It is an object of the present invention to provide a method for manufacturing a cap where the manufacture and installation of the peak assembly can be simplified.
It is a preferred object to provide a method where the peak assembly can be provided with one or more high quality, aesthetic finishes.
It is a further preferred object of the present invention to provide a method where a perspiration absorbing band can easily be provided with the peak assembly.
Other preferred objects of the present invention will become apparent from the following description.
In one aspect, the present invention resides in a method of manufacturing a cap of the type having a dome-like head covering portion and a peak assembly wherein:
the peak assembly has an upturned flange, at or adjacent its rearward end, the flange being fastened to a portion of a rim of the head-covering portion.
Preferably, the flange is rearwardly inclined in the range of 0°-60°, more preferably 30°-45° to the vertical.
Preferably, the flange is formed integrally with the body of the peak from plastics sheet material (eg., by injection moulding), and the upper surface and/or the lower surface of the peak body may be provided with advertising material or other indicia, including printed or painted advertising material, metal foils, decals or like advertising material. The advertising material or other indicia may be received in recess(es) in the upper and/or lower surfaces.
Preferably, the flange is fastened to an intumed and upturned portion of the rim of the head covering portion to conceal the fastening. Preferably, the flange is stitched, glued and/or riveted to the intumed and upturned portion.
A perspiration absorbing band may be stitched or otherwise fastened to the inwardly directed face of the flange.
In a second aspect, the present invention resides in a cap manufactured by the method hereinbefore described.

FIG. 1 is a sectional side view of a prior art cap;
FIG. 2 is a sectional side view of a cap manufactured in accordance with the present invention;
FIG. 3 is a top perspective view of the peak of FIG. 2;
FIG. 4 is a sectional side view, corresponding to FIG. 2, of a second embodiment;
FIG. 5 is a similar view of a third embodiment; and FIG. 6 is a sectional side view of the peak body.

Referring to FIG. 1 , the prior art cap 10 has a domed head covering portion 11 with a peak 12 in the baseball cap style. An adjustment strap (not shown), at the rear of the cap, allows the cap to be worn by persons with different head sizes.
The peak 12 has a peak body 13 (eg., of plastics sheet) enclosed between upper and lower fabric layers 14, 15 which form a "pocket". The fabric layers 14, 15 are stitched at the "mouth" of the "pocket" to an intumed and upturned flange 16 on the rim 17 of the domed head covering portion 11 , and to a flap 19 on a sweat-absorbing band 20 within the head covering portion 11. The stitches are indicated at 21.
Referring to FIG. 2, the peak 112 of cap 110 is formed from a sheet of plastics material (eg., polypropylene, polyethylene, PVC or the like) which is cut and formed (or is, eg., injection moulded) to shape - see FIG. 3.
An upturned flange 126 is provided along the rear end of the body of the peak 112 and is inclined, eg., at an angle α of 30°-45° from the vertical (see FIG. 6).
The plastics material forming the peak 112 may be provided in any one or more selected colours and may be coated, eg., with a gold, silver or chromium metal foil or printed, painted or otherwise coated with advertising material 122, eg., such as an advertiser's logo.
As shown in FIG. 3, the advertising material 122 may be provided in a recess 123 in the upper (or lower) surface of the peak 112.
The head covering portion 111 has an intumed and upturned flap 116 which extends around the rim 117 of the portion.
A sweat absorbing end of material 120 is provided within the head covering portion 111 and has a flap portion 119 in contact with the flange 126.

The flange 126 is sewn between the flaps 116 and 119, eg., by double row stitching 121 , or is affixed thereto by other suitable means, eg., adhesives 221 (see Fig. 4) or rivets 321 (see FIG. 5).
The provision of the flange 126, 226, 326 on the body of the peak 112, 212, 312 enables the peak 112, 212, 312 to be attached to the head-covering portion 111 , 211 , 311 without the need for enclosure of the peak by the upper and lower fabric coverings 14, 15 which limit the finishes/material 122 which may be provided on the peak 112, 212, 312.
It will be readily apparent to the skilled addressee that the body of the peak 112, 212, 312, being of plastics material, enables a wide range of finishes 122 to be displayed, eg., for advertising purposes. For example, an advertiser's logo 128 in silver or gold metal foil (on clear sheet 129) could be placed on the peak, which provides, eg., a contrasting dark coloured background (eg., black, brown, green or blue). The use of such metal foils means that the advertiser's logo can be reflective, further enhancing its recognition value.
Various changes and modifications may be made to the embodiments described and illustrated without departing from the present invention.