Hat Shape-Maintenance Member for Sewing Wrinkle Elimination
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Solution Overview
Problem
Conventional hats experience deformation and wrinkles around the sewing portions due to the tension of flexible tapes, leading to a loosening or shrinking of the exterior shape, which deviates from the initial design, and this deformation is difficult to accurately measure and maintain over time.
Innovation Solution
A hat design incorporating a shape-maintenance enhancing member with a heat-fusion and thermal-fixation layer surrounding the sewing portions, combined with a molding process using a steam mold to prevent contraction and maintain the desired shape, ensuring the hat retains its initial form without unevenness or twist.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a flexible tape is used to surround the sewing portion, then the tape can be smoothly aligned along the curved portion, but the tape causes wrinkles and deformation due to its tension characteristic
Solution Approach 1:
A shape-maintenance enhancing member is introduced as an intermediary component between the flexible tape and the sewing portion. This member includes a heat-fusion layer that is thermally bonded to the sewing portion, creating a stable anchor point that prevents the flexible tape from causing wrinkles and deformation while maintaining smooth alignment along curved portions.
Solution Approach 2:
The shape-maintenance enhancing member utilizes heat-fusion and thermal-fixation properties to change the physical state of the sewing portion. By applying heat during the fusion process, the member becomes permanently attached to the sewing portion, transforming from a temporary alignment aid to a permanent shape-stabilizing component that resists tension-induced deformation.
2Manufacturing precision
If the hat shape is adjusted with a high-temperature steam mold after sewing, then the exterior shape can be restored, but the shape deforms again over time due to gradual contraction
Solution Approach 1:
The shape-maintenance enhancing member is attached to the sewing portion before the final shaping process. This preliminary attachment ensures that the sewing portion is pre-stabilized against contraction and deformation, so that when the steam mold is applied, the shape is set correctly and maintained long-term without recurring deformation.
Solution Approach 2:
The invention replaces the temporary mechanical adjustment method (steam molding) with a permanent thermal bonding system. The heat-fusion layer creates a permanent chemical-physical bond that substitutes for repeated mechanical steam molding, preventing gradual contraction and ensuring long-term shape stability without requiring ongoing adjustments.
3Stability of the object's composition
If additional support bands are added to maintain shape, then the hat can retain its form, but the device complexity increases
Solution Approach 1:
The shape-maintenance enhancing member combines multiple functions into a single integrated component: it provides structural support, prevents wrinkles, anchors the flexible tape, and resists contraction. This merging of functions eliminates the need for separate support bands while maintaining shape stability, thereby reducing overall device complexity.
Solution Approach 2:
The shape-maintenance enhancing member serves multiple purposes simultaneously: it acts as a reinforcement layer, a bonding agent, a wrinkle-prevention element, and a contraction-resistance component. This multi-functionality allows a single component to replace what would traditionally require multiple separate elements, simplifying the overall hat construction.
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 solution effectively stabilizes the hat's shape, preventing contraction and maintaining a smooth exterior and interior appearance over time, ensuring the hat retains its original design without the need for additional support bands.
Implementation Method 1
the main body portion includes a shape-maintenance enhancing layer formed of a material having a heat fusion and thermal fixation property
Implementation Method 2
the shape-maintenance enhancing layer in the main body portion of the shape-maintenance enhancing member is heat-melted between the sewing portion of the head receiving portion and the cover layer of the main body portion and then thermally fixed from cooling
Implementation Method 3
forming the secondarily sewn head receiving portion to the shape of a hat through a molding process using a steam mold
Data Source
AI summary
The present invention relates to a hat using a shape-maintenance enhancing member and a method for manufacturing the same. In particular, the present invention relates to a hat using a shape-maintenance enhancing member that can maintain the exterior appearance of the hat by eliminating wrinkles in a sewing portion using a flexible tape and maintain the shape of the hat to be the same as the initial design, and a method for manufacturing the hat. The shape-maintenance enhancing member according to an exemplary embodiment of the present invention includes a main body portion disposed on the sewing portion and a wing portion surrounding the sewing portion, and the main body portion includes a shape-maintenance enhancing layer formed of a material with properties of heat fusion and thermal fixation and a cover portion connected with the wing portion.