Method for manufacturing hats

Claim 1

A method of installing a band in a hat, comprising the steps of: (a) positioning a piece of fabric relative to a semi-rigid band, said fabric having a first end and a second end, said band having a top edge, a bottom edge and two side edges; (b) fastening said fabric near said first end to said band, said fabric being between said side edges, said fabric further being adjacent said bottom edge and a nominal distance therefrom; (c) positioning said band and attached fabric relative to a hat, said hat having a crown portion defined by a crown surface, and a brim surface disposed substantially normal to said crown surface; (d) fastening said fabric near said second end to said crown surface a nominal distance form said brim surface; (e) rotating said band two times about its longitudinal axis toward and into said hat crown portion; and (f) fastening said band to said crown surface of said hat.

Claim 2

A method of installing a band in a hat, comprising the steps of: (a) positioning a piece of fabric relative to a semi-rigid band, said fabric having a first end and a second end, said band having a top edge, a bottom edge and two side edges; (b) fastening said fabric near said first end to said band, said fabric being between said side edges, said fabric further being adjacent said bottom edge and a nominal distance therefrom; (c) positioning said band and attached fabric relative to a hat, said hat having a crown portion defined by a crown surface, and a brim surface disposed substantially normal to said crown surface; (d) fastening said fabric near said second end to said crown surface a nominal distance form said brim surface; (e) rotating said band two times about its longitudinal axis toward and into said hat crown portion; and (f) fastening said band to said crown surface of said hat.

Claim 11

A method of installing a fabric band in a hat, comprising the steps of: (a) orienting a piece of fabric relative to a hat, said fabric having a first end and a second end, said hat having a crown portion defined by a crown surface, and a brim surface disposed substantially normal to said crown surface; (b) fastening said fabric at a first location near said fabric second end to said crown surface a nominal distance from said brim surface; (c) positioning a semi-rigid stay relative to said fabric first end, said stay having a top edge, a bottom edge and two side edges, wherein said stay bottom edge is disposed a nominal distance form and is adjacent to said fabric first end; (d) rotating said stay two times about its longitudinal axis toward and into said hat crown portion; (e) removing said stay from within said fabric, while maintaining said fabric in intimate contact with said crown surface; and (f) fastening said fabric to said crown surface at a second location near said fabric first end a distance greater than said nominal distance between said first location and said brim surface.

Claim 12

A method of installing a fabric band in a hat, comprising the steps of: (a) orienting a piece of fabric relative to a hat, said fabric having a first end and a second end, said hat having a crown portion defined by a crown surface, and a brim surface disposed substantially normal to said crown surface; (b) fastening said fabric at a first location near said fabric second end to said crown surface a nominal distance from said brim surface; (c) positioning a semi-rigid stay relative to said fabric first end, said stay having a top edge, a bottom edge and two side edges, wherein said stay bottom edge is disposed a nominal distance form and is adjacent to said fabric first end; (d) rotating said stay two times about its longitudinal axis toward and into said hat crown portion; (e) removing said stay from within said fabric, while maintaining said fabric in intimate contact with said crown surface; and (f) fastening said fabric to said crown surface at a second location near said fabric first end a distance greater than said nominal distance between said first location and said brim surface.

Claim 15

A method of installing a ban in a hat, comprising the steps of: (a) trimming a portion of soft cloth to size in proportion to a hat, said soft cloth having a first and a second end, said hat having a crown portion defined by a crown surface, and a brim surface disposed substantially normal to said crown surface; (b) positioning said piece of soft cloth relative to a semi-rigid band, said band having a top edge, a bottom edge and two side edges; (c) stitching said soft cloth near said first end to said band, said soft cloth being between said side edges, said soft cloth further being adjacent said bottom edge and a nominal distance therefrom; (d) positioning said band and attached soft cloth relative to said hat; (e) stitching said soft cloth near said second end to said crown surface a nominal distance from said brim surface; (f) rotating said band two times about its longitudinal axis toward and into said hat crown portion; and (g) riveting said band to said crown surface of said hat.

Claim 16

A method of installing a ban in a hat, comprising the steps of: (a) trimming a portion of soft cloth to size in proportion to a hat, said soft cloth having a first and a second end, said hat having a crown portion defined by a crown surface, and a brim surface disposed substantially normal to said crown surface; (b) positioning said piece of soft cloth relative to a semi-rigid band, said band having a top edge, a bottom edge and two side edges; (c) stitching said soft cloth near said first end to said band, said soft cloth being between said side edges, said soft cloth further being adjacent said bottom edge and a nominal distance therefrom; (d) positioning said band and attached soft cloth relative to said hat; (e) stitching said soft cloth near said second end to said crown surface a nominal distance from said brim surface; (f) rotating said band two times about its longitudinal axis toward and into said hat crown portion; and (g) riveting said band to said crown surface of said hat.