Flip Cap Bill with Segmented Hinge and Oval Snap Closure
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Solution Overview
Problem
Existing flip bill caps have mechanisms that are either expensive or awkward, and their lower bill portions remain flat when flipped open, compromising sun protection and comfort.
Innovation Solution
A pressure point hinge system with precision-cut upper and lower bill portions, oval snap closure design, and rivets ensure the cap maintains a natural curve and secure locking, while using satin cloth fabric for increased bendability and durability, allowing for improved sun protection and comfortable fit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a traditional flip bill mechanism is used, then the bill can be flipped open to display information, but the mechanism becomes expensive and awkward
Solution Approach 1:
The bill is divided into an upper bill portion and a lower bill portion that can move independently relative to each other. The upper bill portion is segmented into a display surface and side portions that connect to the lower bill portion, allowing the display surface to flip open while the connection portions maintain the hinge mechanism simplicity
Solution Approach 2:
The complex internal mechanism is extracted and replaced by utilizing the flexibility and natural movement of the bill material itself. The hinge functionality is achieved through the flexible connection portions rather than through complex mechanical joints, reducing overall device complexity
2Area of stationary object
If the lower bill portion is made straight when flipped open, then the artwork display area is maximized, but sun protection and comfort are compromised
Solution Approach 1:
The lower bill portion is designed to maintain its natural curved shape when the upper bill portion is flipped open, rather than becoming straight. This curvature is achieved through the flexible connection portions that allow the lower bill to retain its arch shape, providing both sun protection and comfort while still enabling artwork display
3Area of stationary object
If the lower bill portion is made straight when flipped open, then the artwork display area is maximized, but comfort is compromised
Solution Approach 1:
The lower bill portion maintains its natural curved shape through the flexible connection design, preserving the ergonomic comfort associated with curved bills while still allowing the upper bill to flip open for artwork display. The curvature provides a more comfortable fit against the wearer's face
4Area of stationary object
If the upper and lower bills are made completely separate entities with precision cutting, then maximum surface area for artwork is achieved, but manufacturing precision requirements increase
Solution Approach 1:
The bill is segmented into upper and lower portions with specific connection portions that require precise cutting to create the hinge mechanism. The precision cutting creates functional hinges that enable the upper bill to flip while maintaining structural integrity, and this segmentation allows maximum artwork surface area on the upper bill display surface
Data Source
AI summary
A flip cap which has crown and bill portions, the bill having upper and lower members, at least one of the upper and lower members having a surface capable of displaying info nation secured thereto when the upper and lower members are spaced-apart.The lower and upper bill members are secured in a first position to each other by using a plurality of holes formed in the upper bill member and a plurality of aligned pin members formed in the lower bill member, a lower edge formed on the upper bill member enabling it to engage at least two of the pin members formed on the lower bill member when the lower and upper bill members are spaced-apart, thereby maintaining the lower and upper bill members in the spaced-apart position.