Cap Protector Shell with Locking Mechanism
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Solution Overview
Problem
Existing methods fail to effectively protect ball caps from deformation, dust, mold, and fading during storage and transport, leading to damage and loss of value, especially for collector's items.
Innovation Solution
A unitary, rigid shell with a planar panel and locking mechanism that securely holds the cap's bill and crown, preventing deformation and damage, constructed from lightweight materials like polypropylene plastic.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the cap is stored on a shelf, then it is easily accessible, but it collects mold and dust
Solution Approach 1:
The cap is nested inside a protective shell that seals it from the external environment. The shell acts as a container within which the cap is stored, preventing direct contact with dust and mold-spore-laden air while maintaining easy accessibility by simply opening the shell.
2Illumination intensity
If the shelf is exposed to sunlight, then the area is well-lit, but the cap's fabric or logo fades significantly
Solution Approach 1:
The cap is stored within a protective shell that shields it from sunlight exposure. The shell acts as a barrier between the cap and the illuminating environment, preventing UV-induced fading while allowing the storage area to remain well-lit for visibility.
3Quantity of substance
If multiple caps are stacked, then storage space is optimized, but the lowermost caps get crushed and deformed
Solution Approach 1:
Each cap is individually nested within its own protective shell, creating discrete units that can be stacked without direct contact between caps. The rigid shells distribute and absorb stacking forces, preventing deformation of the caps while maximizing vertical storage space.
Solution Approach 2:
The rigid protective shell is designed beforehand to withstand crushing forces. By placing the cap inside this pre-engineered protective structure, the cap is shielded from deformation forces that would occur during stacking, before the actual stacking action takes place.
4Ease of operation
If the cap is suspended by the rear adjustment strap, then it is easy to store, but the cap elongates and fits poorly
Solution Approach 1:
The cap is nested within a protective shell that provides structural support and maintains the cap's original shape. This eliminates the need to suspend the cap by its strap, as the shell itself provides the storage function without causing deformation.
5Weight of moving object
If the cap is transported in a suitcase, then it is portable, but the crown is compressed and the bill bends
Solution Approach 1:
The cap is nested within a rigid protective shell that acts as a protective container during transport. The shell's rigid structure prevents external forces from compressing the crown or bending the bill, while the overall assembly remains portable for inclusion in suitcases or luggage.
Solution Approach 2:
The rigid protective shell is designed beforehand to withstand compression and bending forces. By placing the cap inside this pre-engineered protective structure before transport, the cap is shielded from deformation forces that would occur during suitcase transport, without significantly increasing weight.
Data Source
AI summary
A cap protector includes a unitary rigid shell having an open rear in communication with an interior chamber that is dimensioned and configured to receive the crown portion of a cap. Integrally extending from the lower, front portion of the shell is a substantially planar panel configured to resemble the cap's bill. The panel includes a slot in communication with an interior cavity that is dimensioned to firmly receive the cap bill. On the upper surface of the shell is a grommet with a locking mechanism that grips the cap's crown button.