Process for the production of a recoverable flexible sun visor core

Abstract

A hat comprising a shape-adjustable brim or visor made of a shape memory plastic composite, a hat (e.g. a fedora and a panama) comprising such a shape-adjustable brim or visor, and a method of manufacturing the above-mentioned hats.

Description

Technical Field

[0001] This invention relates to the field of hats, and in particular to a manufacturing process for a reversible, flexible visor core. Background Technology

[0002] People choose to wear brimmed or brimless hats for various reasons or purposes, or simply to suit different occasions. For example, many people wear hats while playing sports such as baseball, softball, tennis, cross-country running, hiking, cycling, and so on. Many people may choose to wear hats simply for sun protection or other weather conditions, while others may do so purely for aesthetics or fashion. Therefore, wearers of brimmed or brimless hats may desire different shapes for the brim or visor to suit various purposes. Although existing brimless or brimmed hats on the market have slightly different shapes for the visor or visor, such as flat, curved, or other styles, and some are even adjustable to a certain extent, overall, the shape of these hats is usually fixed and cannot be adjusted to suit the wearer's needs.

[0003] Some people may attempt to alter the shape of the brim of a brimmed hat or the visor of a brimless hat to create a certain curve or style, but the results are not always satisfactory. These methods are tedious and time-consuming, and can cause permanent damage to the brimmed or brimless hat, sometimes making it impossible to restore the hat to its original shape.

[0004] Although existing technologies have proposed some solutions to address the problems in the current technology, the success rate is low. For example, Tai Kuang Wang proposed installing flexible metal or rubber tubes along the edge of the brim of a brimmed hat or the visor of a brimless hat (US 2004 / 0000004 A1), or manufacturing the brim or visor plate using metal mesh materials including aluminum, iron, copper, titanium, nickel, stainless steel, etc., coated with various plastic materials (US

[0005] (2004 / 0123376A1). Other options can be found in US 2004 / 0194192 A1, US11178928 B2, US11445776B2, KR101843357 B1, etc.

[0006] However, the visors of the various brimless hats disclosed in the prior art all have various drawbacks, such as relying on the use of metal materials to achieve elasticity, which increases the difficulty or cumbersomeness of forming and reforming, and may be permanently damaged after a limited number of repetitions. In addition, the manufacturing process of brimless hats with such visors can be lengthy and expensive.

[0007] Therefore, it is necessary to develop new materials and processes to manufacture the visor of brimless hats or the brim of brimmed hats, so that the shape of the visor or brim can be adjusted according to the wearer's preference and easily transformed into the desired shape. Summary of the Invention

[0008] The present invention provides a solution that uses a novel plastic composite material to meet the aforementioned requirements. This novel plastic composite material can be used to manufacture hats with adjustable visors or brims.

[0009] One object of the present invention is to provide a hat with an adjustable visor or brim that allows the wearer to bend the visor or brim from a flat surface into a curved shape according to the wearer's preference.

[0010] Another object of the present invention is to provide a hat with an adjustable visor or brim that is easily deformed by hand and retains the changed shape.

[0011] Another object of the present invention is to provide a hat with an adjustable visor or brim that is easily deformed by hand and returns to its original shape.

[0012] In a first aspect, the present invention provides a shape-adjustable brim or visor of a hat. The brim or visor includes a resilient plate that can be manually adjusted to a desired curved shape and return to its original flat shape, wherein the resilient plate constituting the core of the brim or visor is made of a shape memory plastic composite material. In a preferred embodiment, the shape-adjustable brim or visor of the hat is made of a shape memory plastic composite material comprising low-density polyethylene and high-density polyethylene.

[0013] On the other hand, the present invention provides a hat comprising a brim or visor according to any of the disclosed embodiments and a body portion covering the wearer’s head, wherein the brim or visor is sewn to the body along the bottom edge of the body and protrudes outward from the body portion to shield from sunlight or protect against weather conditions.

[0014] On the other hand, the present invention provides a method for preparing a shape memory plastic composite material suitable for manufacturing the brim or visor of a hat.

[0015] On the other hand, the present invention provides a method for manufacturing the brim or visor of a hat from a shape memory plastic composite material.

[0016] On the other hand, the present invention provides a method for manufacturing a hat (e.g., a brimmed hat or a brimless hat) with a shape memory brim or visor.

[0017] The hat of this invention allows the wearer to customize the shape of the visor or brim to their liking and restore it to its original flat shape as needed for easy wearing or storage. Manufacturing such a hat using the innovative visor or brim is simple and requires no complex processes, unlike any existing manufacturing method.

[0018] Other aspects, features, and advantages of the invention will become more apparent from the following detailed description taken in conjunction with the accompanying drawings. Attached Figure Description

[0019] The image shown below is a snapshot from a video clip demonstrating the operation of a brimless hat with an innovative visor, showing how the shape of the visor is adjusted by hand from a flat shape to a curved shape and then back to the original flat shape.

[0020] Figure 1 A perspective view of a brimless cap with a flat, shape-adjustable brim and an adjustable brim, according to an embodiment of the present invention, is shown.

[0021] Figure 2 Another perspective view of a brimless cap with the brim in the process of bending is shown;

[0022] Figure 3 Another perspective view of a brimless cap is shown, showing the cap retaining its curved shape on a flat surface after the brim has been manually bent. Detailed Implementation

[0023] This invention provides an innovative shape-memory plastic composite material for use in hats with adjustable brims or visors. The plastic composite material possesses shape-memory properties, allowing the brim or visor of a hat, initially manufactured in a flat shape, to be manually adjusted into a curved shape. The degree of curvature can be manually adjusted before wearing according to the wearer's preference. After use, the wearer can easily adjust the brim or visor back to its original flat shape.

[0024] Therefore, in a first aspect, the present invention provides a shape-adjustable brim or visor for a hat. The brim or visor includes a resilient plate that can be manually adjusted to a desired curved shape and reverted to its initial flat shape, wherein the resilient plate is made of a shape memory plastic composite material.

[0025] In one embodiment, the shape-adjustable brim or visor of the hat is made of a shape memory plastic composite material, which includes low-density polyethylene and high-density low-density polyethylene.

[0026] In one embodiment, the shape memory plastic composite material further includes one or more components selected from nanopowder, active calcium, plastic lubricant, polyethylene (PE) composite modifier, pigment, titanium dioxide, antioxidant, AC foaming powder, zinc stearate, stearic acid and diffusion powder.

[0027] In one implementation, the hat is either a brimmed hat or a brimless hat.

[0028] In one embodiment, the brimmed or brimless hat includes a hat body whose size and shape are substantially matched to a person's head for comfortable wearing, wherein the brim or visor is placed along the bottom edge of the hat body and extends outward from the hat body.

[0029] In one implementation, the brim or visor is covered by an outer cover.

[0030] In one embodiment, the outer cover includes an upper cover located above the brim or visor and a lower cover located below the brim or visor.

[0031] In one embodiment, the upper and lower covers are sewn together with the brim or visor to form a single brim or visor.

[0032] In one embodiment, a padding is inserted between the upper hood and the brim or visor and / or between the lower hood and the brim or visor.

[0033] In one implementation, the dimensions of the upper cover, lower cover, and padding (if any) are the same as or substantially the same as the dimensions of the brim or visor.

[0034] On the other hand, the present invention provides a hat comprising a brim or visor according to any of the disclosed embodiments and a body portion covering the wearer’s head, wherein the brim or visor is sewn to the body along the bottom edge of the body and protrudes outward from the body portion to shield from sunlight or protect against weather conditions.

[0035] In one embodiment, in a brimless cap comprising a visor and a body, the visor includes a substantially flat shape memory plate, such that the visor can be manually bent by the wearer to form a desired curved shape and subsequently revert to its original flat shape as needed.

[0036] On the other hand, the present invention provides a method for manufacturing a brim or visor of a hat made of shape memory plastic composite material, the method comprising the following steps:

[0037] (a) High-density polyethylene (HDPE), linear low-density polyethylene (LLDPE) and nano-modified materials are mixed at high speed (e.g., about 1200 RPM);

[0038] (b) Add the excipients in proportion, heat the mixture to about 80°C, and then stir (e.g., about 720 RPM) for 2 hours;

[0039] (c) The obtained material is completely dried and allowed to stand at about 50°C to release it;

[0040] (d) Transfer to an automated loading machine equipped with a strong magnetic field and a filtering device (e.g., to remove debris, such as iron filings);

[0041] (e) Transfer to the extruder hopper, heat the screw to about 185°C, and then extrude at a low speed (e.g., 600 RPM);

[0042] (f) Initial forming of the die head, the thickness (tolerances should be controlled (left, middle and right sides) to be accurate to about 0.1 mm;

[0043] (g) Allow natural air to cool and set the shape for about 5 minutes;

[0044] (h) Heat the oven to about 195°C, and then perform a second plasticizing of the material;

[0045] (i) Punch to the required width, for example, 22cm, accurate to 0.5cm; and

[0046] (j) Formed into a U-shaped groove bent plate at approximately 100°C;

[0047] (k) Cool the U-shaped plate in a U-shaped groove with strong natural air for about 25 minutes to obtain the U-shaped plate;

[0048] (l) After the U-shaped plate cools, eject the material and load it into a frame, then let it stand for at least 48 hours; and

[0049] (m) Use a fully automatic punch press to press a cooled U-shaped plate to obtain a flat shape memory brim or visor plate.

[0050] On the other hand, the present invention provides a method for manufacturing a hat with a shape-memory brim or visor, the method comprising:

[0051] (a) Providing a shape-memory brim or visor plate manufactured according to the method disclosed herein, and covering the brim or visor plate with a required covering fabric to create a brim or visor plate, optionally, inserting a padding between the covering fabric layer and the shape-memory brim or visor plate; and

[0052] (b) Provide a hat body that matches the size of the brim or visor, and sew the brim or visor along the bottom edge of the hat body to obtain the brim of the hat.

[0053] In one implementation, the hat is a brimmed hat that includes a shape-memory brim.

[0054] In one implementation, the hat is a brimless hat that includes a shape-memory visor.

[0055] On the other hand, the present invention provides a plastic composite material that is elastic and has shape memory properties.

[0056] On the other hand, the present invention provides a method for producing a plastic composite material that is elastic and has shape memory properties.

[0057] Plastic composite materials can be made into flat sheets with a thickness suitable for manufacturing the brim or visor of a hat as needed. The flat sheets are cut into the shape of the visor or visor according to the design and size of the hat. The visor or visor can be made according to any conventional method known in the art, by combining the cut sheets into a single component, so that the visor or visor has shape memory properties after being placed along the bottom edge of the hat body.

[0058] Referring to the attached image, taking a brimless cap with an innovative visor as an example, Figure 1 A perspective view of a brimless cap with a flat, shape-adjustable visor according to an embodiment of the invention is shown. The visor is made of a shape-memory plastic composite sheet. The brimless cap has a flat visor with an "original" or "default" shape. Figure 2 A perspective view of a brimless cap with an adjustable brim is shown, where the brim can be manually bent by the wearer. Figure 3 Another perspective view of a brimless cap with an adjustable brim is shown, in which the wearer manually bends the brimless cap so that the brim retains its curved shape in a plane after manual adjustment.

[0059] Specifically, unlike the visor of a conventional brimless cap, which is usually made of low-density high-density polyethylene, the visor or brim of this invention is made of special EVA with a specific mixing ratio, which gives the visor or brim shape memory properties.

[0060] As used herein, the singular forms “a” and “the” include plural meanings, and vice versa, any plural form includes singular meanings unless the context clearly specifies otherwise.

[0061] Unless otherwise defined, the terms “about” or “approximately” generally include ±10% of the value indicated. For example, “about 10%” could represent a range of 9% to 11%, while “about 20%” could represent a range of 18% to 22%. Sometimes, preferably, “about” includes ±5% of the value indicated. Alternatively, “about” includes ±5% of the value indicated. When “about” is used before a range, it applies to both the lower and upper limits of the range.

[0062] As used herein, the term “substantially” means “mostly” or “substantially” as understood by one of ordinary skill in the art, and if quantifiable, means at least 90%, preferably at least 95%, more preferably at least 98%.

[0063] Unless otherwise stated, the terms “including,” “having,” and other forms of inclusion should be interpreted as open-ended terms (i.e., meaning “including, but not limited to”).

[0064] The following non-limiting embodiments further illustrate certain aspects of the invention.

[0065] Example

[0066] Preparation of shape memory plastic composite materials

[0067] Shape memory plastic composite materials are prepared using the process described in the following exemplary procedure: feeding (HDPE, LLDPE, and nano-modified materials) -> high-speed stirring for 30 minutes -> adding proportioned excipients -> heating to 80°C, then stirring for 2 hours -> raw materials are completely dried and allowed to stand at 50°C before release -> automatic feeder with strong magnetic force and filtration -> conveyed to the extruder hopper -> screw heating to 185°C for high-temperature low-speed extrusion -> initial die shaping, thickness accurate to 0.1mm -> natural air cooling and shaping for 5 minutes -> oven heating to 195°C for secondary plasticizing and shaping -> punching and shearing to standard width, accurate to 0.5cm -> ejecting a U-shaped groove bending plate at approximately 100°C for shaping -> U-shaped groove cooling with strong air and natural air for 25 minutes -> ejecting the U-shaped plate after cooling, framing, and allowing it to stand for more than 48 hours -> punching standard die-cutting of the finished cap tongue core -> finished product inspection and packaging.

[0068] To prepare 120 kg of composite material, the following raw materials were used: 75 kg high-density low-pressure polyethylene, 25 kg low-density high-pressure polyethylene, 11.6 kg (nanopowder + active calcium), 4 kg plastic lubricant, 5 kg polyethylene (PE) composite modifier, 0.6 kg (pigment + titanium dioxide), 0.2 kg antioxidant, 0.45 kg AC foaming powder, 0.45 kg zinc stearate, 0.3 kg stearic acid, and 0.05 kg diffusion powder.

[0069] Using any method known to those skilled in the art, for example as described in any of the foregoing patent references, the U-shaped plate obtained by the above process can be made into different shapes as needed for the visor of a brimless hat or the brim of a brimmed hat. Although the invention has described a brimless hat as an example, the invention is not limited to brimless hats, but may include, but is not limited to, brimmed hats, sun hats, or other kinds of hats with a visor or brim portion.

[0070] The foregoing embodiments and examples are for illustrative purposes only and are not intended to limit the exact structures and operations shown and described. Various modifications and variations can be conceived by those skilled in the art without departing from the spirit and scope of this invention, and all such modifications and variations are within the scope of this invention. For all purposes, all patent references cited herein are incorporated herein by reference in their entirety.

Claims

1. A method for making a hat with an adjustable brim or visor, characterized in that, The brim or visor includes a flexible plate that can be manually adjusted into a curved shape and reverted to its original flat shape, wherein the flexible plate is made of a shape memory plastic composite material; The hat is a brimmed or brimless hat, comprising a hat body whose size and shape are substantially matched to a person's head for comfortable wear. The brim or visor is positioned along the bottom edge of the hat body and extends outwards from it. The brim or visor is covered by an outer cover. The outer cover comprises an upper cover located above the brim or visor and a lower cover located below the brim or visor. The upper and lower covers are sewn together with the brim or visor to form a single brim or visor. Padding is inserted between the upper cover and the brim or visor and / or between the lower cover and the brim or visor. The dimensions of the upper cover, the lower cover, and the padding are the same as or substantially the same as the dimensions of the brim or the visor. The method includes: (a) High-density polyethylene (HDPE), linear low-density polyethylene (LLDPE), and nano-modified materials were mixed at high speed. To prepare 120 kg of shape memory plastic composite material, the following raw materials were used: 75 kg of high-density low-pressure polyethylene, 25 kg of low-density high-pressure polyethylene, 11.6 kg of nano powder + active calcium, 4 kg of plastic lubricant, 5 kg of polyethylene (PE) composite modifier, 0.6 kg of pigment + titanium dioxide, 0.2 kg of antioxidant, 0.45 kg of AC foaming powder, 0.45 kg of zinc stearate, 0.3 kg of stearic acid, and 0.05 kg of diffusion powder. (b) Add the excipients in the specified proportion and heat the mixture to 80°C while stirring; (c) Dry the obtained material and allow it to stand at 50°C to obtain a mixture for release; (d) The mixture is transferred to the extruder hopper, the screw is heated to 185°C, and then extruded at a low speed; (e) Forming the extruded material from step (d) into a sheet, including: (i) Initial forming of the die head, with a thickness accurate to 0.1 mm; (ii) Allow natural airflow to cool and set the shape for 5 minutes; (iii) Heat to 195°C and then perform a second plasticization on the material; (iv) Punch to standard width, accurate to 0.5 cm; and (v) Formed into a U-shaped groove bent plate at 100°C; (f) Cool the plate in a U-shaped groove with natural air for 25 minutes to obtain a U-shaped plate; (g) After the U-shaped plate has cooled, the material is ejected and placed in a frame, and left to stand for at least 48 hours; and (h) Stamping and cooling U-shaped plates to obtain a flat shape memory brim or visor.

2. A method for manufacturing a hat including a shape memory visor, characterized in that, Includes the following steps: (a) Providing a shape memory brim or visor plate manufactured according to the method of claim 1, and covering the brim or visor plate with the required covering fabric to make a brim or visor plate, optionally, inserting a pad between the covering fabric layer and the shape memory brim or visor plate; as well as (b) Provide a hat body that matches the size of the brim or the visor, and sew the brim or the visor to the hat body along the bottom edge of the hat body to obtain the brim of the hat.

3. The method of claim 2, wherein, The hat is a brimmed hat that includes a shape-memory brim.

4. The method of claim 2, wherein, The hat is a brimless hat that includes a shape-memory visor.

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