Laminated Cork Visor Board for Water-Resistant Brim Support

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Solution Overview

Problem

Existing visor boards in headgear brims are made from materials like plastic, foam, cardboard, and solid wood, which are not biodegradable, prone to deformation, water damage, or structurally inadequate, posing environmental and functional challenges.

Innovation Solution

A visor board constructed with laminated cork and optional strengthening materials like bamboo, fabric, or wood, which are sewable, flexible, waterproof, and exhibit rebound properties, providing structural integrity and reducing environmental impact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If plastic visor boards are used, then structural support and shape retention are improved, but biodegradability deteriorates and environmental pollution increases

Engineering Contradiction:

Improvestructural supportVSAvoidenvironmental pollution

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The patent changes the material parameter from synthetic plastic to natural cork, transforming the visor board from non-biodegradable to biodegradable while maintaining structural support capabilities through cork's natural properties

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses composite construction by laminating multiple cork layers together to create a visor board that combines the structural strength normally associated with plastic with the biodegradability of natural materials

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If plastic visor boards are used, then ease of manufacture is improved, but resistance to deformation deteriorates when bent beyond threshold pressure

Engineering Contradiction:

Improvemanufacturing easeVSAvoidresistance to deformation

Core Design Contradiction:

Ease of manufactureVSStability of the object's composition

Solution Approach 1:

The patent divides the visor board into multiple thin cork layers that are laminated together, allowing each layer to flex independently while maintaining overall structural integrity when bent

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The laminated cork construction creates a composite material that combines flexibility with structural stability, enabling the visor board to withstand bending without permanent deformation

Inventive Principle:

Principle #40Composite materials

3Object-generated harmful factors

If cardboard is used for visor boards, then biodegradability is improved, but water-resistance deteriorates

Engineering Contradiction:

ImprovebiodegradabilityVSAvoidwater damage

Core Design Contradiction:

Object-generated harmful factorsVSObject-affected harmful factors

Solution Approach 1:

The patent changes the material parameter from cardboard to cork, which naturally possesses water-resistant properties due to its cellular structure containing suberin, a waterproofing substance

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The laminated cork construction creates a water-resistant barrier while maintaining biodegradability, as cork's natural composition resists water penetration yet remains environmentally friendly

Inventive Principle:

Principle #40Composite materials

4Strength

If solid wood is used for visor boards, then strength is improved, but weight increases and ease of manufacture deteriorates

Engineering Contradiction:

Improvestructural strengthVSAvoidweight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent divides the solid wood structure into multiple thin cork layers, reducing the overall weight while maintaining structural strength through the distributed laminate construction

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent changes from dense solid wood to lighter cork material, reducing weight while maintaining sufficient structural strength for visor board application

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The cork-based visor boards offer durability, water-resistance, and flexibility, meeting or exceeding the performance of plastic brims in terms of flex, heat-moldability, and comfort, while being biodegradable and reducing pollution.

Implementation Method 1

The visor board is a rigid or flexible material used to provide the shape and structure of the brim element... have some ability to return to their original shape, sometimes referred to as 'rebound'

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

cork-based visor boards offer durability, water-resistance, and flexibility

Methodology Applied

Scientific EffectHydrophobicity: Hydrophobe

Data Source

PatentUS12588725B2Visor board for use with headgear brim

Publication Date: 2026.03.31 RUSTEK COLLECTIVE LLC

AI summary

A visor board for use in a headgear brim comprising a multilayer structure having a layer of cork and a layer of a strengthening material laminated to the layer of cork. Other material combinations for a visor board of a headgear brim are provided.