AU2015100610A6 - Foldable Hat - Google Patents

Abstract

Abstract A folding hat formed from sheet material, including: A crown and a brim connected such that the brim is moveable relative to the crown between a first configuration whereby the hat is in an erected condition and a second configuration whereby the hat is able to be folded substantially flat. Preferably, the crown is shaped such that when folded substantially flat, the top of the crown has a first width and the bottom of the crown has a second width, whereby the second width is greater than the first width and the sides taper between them. Correspondingly, the inner edge of the brim, when folded may have a third width, that is preferably less than the second width of the crown and equal to or greater than the first width of the crown, such that to fold flat, the brim must be moved to a point along the height of the crown where the inner edge of the brim has a greater width than the width of the crown. (o \6 FIGURE 1

Description

2 Foldable hat Field of the invention The present invention relates to folding hats folded from sheet material, most preferably, though not exclusively, paper. 5 Background of the invention It is known to provide hats constructed from paper sheet. For example, US Patent No 4,429,420 discloses a cowboy hat formed from a single sheet of paper-board which is cut and scored. However, this hat, once assembled takes up a large amount of space for transport and requires complete disassembly to be able to be stacked flat. 10 Folding hats are also known, but their appearance is generally box-like, and therefore uncomfortable and unattractive to wear. The applicant has seen a need for an improved construction method for foldable hats for providing an improved shaping to the hat. The applicant has also determined that the folding hat may be an opportunity for branding/promotion, and/or may have a 15 uniquely cultural flavour (e.g. Australian, American, Mexican etc.), such that it can be used for promotions at cultural events such as, for example, sporting events which have a cultural significance within any given country/region. The applicants earlier patent application PCT/AU2011/001335 sought to overcome the above disadvantages. However, in order to fold the hat once constructed, 20 pleating is required in the brim portion. The applicant sought to provide an alternative construction that negated the need for pleating of the brim portion. The present invention therefore seeks to provide an alternative folding hat formed from sheet material that overcomes or at least alleviates one or more disadvantages associated with previous folding paper hats. 25 3 Reference to any prior art in the specification is not an acknowledgment or suggestion that this prior art forms part of the common general knowledge in any jurisdiction or that this prior art could reasonably be expected to be understood, regarded as relevant, and/or combined with other pieces of prior art by a skilled person 5 in the art. Summary of the invention First to fourth aspects According to a first aspect, there is provided a folding hat formed from sheet material, including: 10 a crown and a brim connected such that the brim is moveable relative to the crown between a first configuration whereby the hat is in an erected condition and a second configuration whereby the hat is able to be folded substantially flat. Preferably, the crown is shaped such that when folded substantially flat, the top of the crown has a first width and the bottom of the crown has a second width, whereby 15 the second width is greater than the first width and the sides taper between them. Correspondingly, the inner edge of the brim, when folded may have a third width, that is preferably less than the second width of the crown and equal to or greater than the first width of the crown, such that to fold flat, the brim must be moved to a point along the height of the crown where the inner edge of the brim has a greater width than the width 20 of the crown. According to a preferred embodiment, the crown and brim are connected in a sliding arrangement such that the brim may be slid up and down the height of the crown. Advantageously, the sides of the crown include two spaced apart slots extending a portion of the height of the crown. The sides of the brim may include corresponding 25 loops that connect to respective slots in a sliding fashion. In the first configuration, the loops are positioned at the bottom of the slots, such that the brim sits around the lower portion of the crown. Engagement tabs may be used to removably interconnect the brim to the crown at the front and rear. In the second configuration, the loops are preferably positioned at the top of the slots, such that the inner edge of the brim is able to be 4 folded flat around the outside of the crown. Advantageously, the length of the slots are directly proportional to the inside diameter of the brim, but may be greater or less. Alternative connections are also envisaged. One such connection could be two or more tabs connected between the crown and the brim, the tabs having a first length 5 in the first configuration and a second length in the second configuration. As such, the tab may be folded in a concertina arrangement, such that in the first length the tab is folded to a shorter length than the second length where the tab is extended. The present invention preferably allows the hat to be folded whilst the brim is connected to the crown, advantageously without requiring pleats to be formed in the 10 brim, such that the brim is only folded at two opposing fold lines. The fold lines may be positioned at the front and rear of the hat, whereby the sliding arrangement is located at the sides of the hat, such that when folded, the respective sliding arrangements sit against each other and the crown may be folded in half. The crown of the hat is preferably made from a single sheet of paper, having one 15 or two seams down the height of the crown. In a first embodiment, the upper portion of the crown includes a central fold line, with the upper and lower edges of the crown walls being curved. When folded, the upper portion sits upward of the upper edges of the crown walls creasing at the central fold line. When erected, the central fold line may be pushed downwardly to become indented and form a concave top surface from the 20 curved upper edges of the crown wall, facilitating the holding of the structure of the crown. In a second embodiment, the crown is conical, tapering up the height of the walls to a point. The brim is advantageously of an oval shape, having an outer rim and an inner 25 rim. The loops preferably project from the inner rim and may be formed from two arms that are inserted through respective slots wrapping around to join on the inside of the crown. The two arms may join by sliding together corresponding opposing notches such that additional fasteners are not required.

5 According to a second aspect, there is provided a method of forming a hat, including the steps of: forming a brim from a first sheet portion, the brim including loop means; forming a crown from a second sheet portion, the crown including at least one set 5 of slots extending in a direction of the height of the crown; attaching the brim to the crown by positioning the loop means through the slots and securing in place; wherein the brim is connected to the crown in a sliding arrangement such that the brim is moveable relative to the crown between a first configuration whereby the 10 hat is in an erected condition and a second configuration whereby the hat is able to be folded substantially flat. According to a third aspect, there is provided a method of assembling a hat from a sheet to a flat deconstructed hat, the hat being a hat as described in the first aspect, the method including the steps of: 15 forming the brim from a first sheet portion; forming the crown from a second sheet portion; connecting the brim to the crown in a sliding arrangement such that the brim is moveable relative to the crown between a first configuration whereby the hat is in an erected condition and a second configuration whereby the hat is able to be 20 folded substantially flat. According to a fourth aspect, there is a method of erecting a hat from a flat condition to an erect condition, the hat being a hat as described in the first aspect, the method including the steps of: moving the brim from the second configuration to the first configuration by sliding 25 the brim downwards with respect to the crown and opening the crown. Fifth to eight aspects 6 According to a fifth aspect, there is provided a folding hat formed from sheet material, including: a crown and a peak attached to the crown, whereby the crown is formed from two flaps that are positioned to overlap and fasten together at a central region such that the 5 two flaps can rotate with respect to each other to move between a first configuration to form the structure of the crown, opening the peak and a second configuration to enable the crown and peak to fold flat. The crown is preferably formed from a single sheet of material, but may be formed from two sheets joined together. The two flaps are advantageously of an hour 10 glass shape. The central regions are preferably fastened together by a central pivot pin. The peak is preferably attached at respective rear points to respective sides of the crown, advantageously at points where the two flaps intersect and join together. In the erected position the peak may be held in place by including a projection that slots into a slit provided in the front of the crown. 15 According to a sixth aspect, there is provided a method of forming a hat, including the steps of: forming a crown from sheet material including two overlapping flaps and securing them at a central region such that they are able to rotate with respect to each other; forming a peak from sheet material, the peak having two rear points; 20 fastening two flaps together at their respective lower ends, with the rear points of the peak attaching to lowers ends of one or more flaps; whereby the two flaps can rotate with respect to each other to move between a first configuration to form the structure of the crown, opening the peak to a second configuration to enable the crown and peak to fold flat. 25 According to a seventh aspect, there is provided a method of assembling a hat from a sheet to a flat deconstructed hat, the hat being a hat as described in the fifth aspect, the method including the steps of: 7 forming a crown from sheet material including two overlapping flaps and securing them at a central region such that they are able to rotate with respect to each other; forming a peak from sheet material, the peak having two rear points; fastening two flaps together at their respective lower ends, with the rear points of 5 the peak attaching to lowers ends of one or more flaps; rotating the two flaps with respect to each other to move from a first configuration to form the structure of the crown to a second configuration folding the crown and peak flat. According to an eighth aspect, there is a method of erecting a hat from a flat 10 condition to an erect condition, the hat being a hat as described in the fifth aspect, the method including the steps of: spreading slightly the lower ends of the flaps, pushing downwardly on the central region of the crown and rotating the two flaps with respect to each other to form the structure of the crown. 15 Ninth aspect According to a ninth aspect, there is provided a folding hat formed from a single piece of sheet material, including: a first side and a second side being joined together by a central portion, each of the sides including a crown portion and a brim portion integrally formed, the edges of 20 the first side joining to respective edges of the second side; the central portion having a middle section connected to the first and second sides and outer sections not connected to the first and second sides; whereby the middle section has a central fold line in a first direction and the outer sections have at least one fold line in a second direction, such that when folded, the 25 outer sections fold inwardly under the middle section.

8 The hat when erected advantageously takes the shape of what is commonly known as a bucket hat. Advantageously, the central portion has a shape corresponding to the internal shape of the top of the crown when erected. 5 The shape of the crown when erected is typically of a generally oval shape with points at the side seams. The middle section is preferably two trapezoids meeting at the central fold line across their shorter length. The outer edges of the outer sections are preferably shaped like a pointed or equilateral arch. The inner edges follow the sides of the trapezoidal middle section. 10 The upper edge of the crown is preferably straight, whilst the lower edge of the crown is preferably curved, with the lower edge of the brim being similarly curved. Further aspects of the present invention and further embodiments of the aspects described in the preceding paragraphs will become apparent from the following description, given by way of example and with reference to the accompanying drawings. 15 Brief description of the drawings The invention will now be described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 is a perspective view of a folding hat according to a first embodiment of the first aspect of the invention, in an erected condition; 20 Figure 2 is a blank for the crown portion of the folding hat of Figure 1; Figure 3 is a blank for the brim portion of the folding hat of Figure 2; Figure 4 is a side view of the folding hat of Figure 1, assembled and in a folded condition; Figure 5 is a top view of the folding hat of Figure 1, in an erected condition; 25 Figure 6 is a bottom view of the folding hat of Figure 1, in an erected condition; Figure 7 is a side view of the folding hat of Figure 1, in an erected condition; 9 Figure 8 is a front view of the folding hat of Figure 1, in an erected condition; Figure 9 is a perspective view of a folding hat according to a second embodiment of the first aspect of the invention, in an erected condition; Figure 10 is a blank for the crown portion of the folding hat of Figure 9; 5 Figure 11 is a blank for the brim portion of the folding hat of Figure 9; Figure 12 is a side view of the folding hat of Figure 9, assembled and in a folded condition; Figure 13 is a top view of the folding hat of Figure 9, in an erected condition; Figure 14 is a bottom view of the folding hat of Figure 9, in an erected condition; 10 Figure 15 is a side view of the folding hat of Figure 9, in an erected condition; Figure 16 is a front view of the folding hat of Figure 9, in an erected condition; Figure 17 is a perspective view of a folding hat according to the fifth aspect of the invention, in an erected condition; Figure 18 is a side view of the folding hat of Figure 17, assembled and in a folded 15 condition; Figure 19 is a blank for the folding hat of Figure 17; Figure 19A is the crown blank shown in Figure 19 with one flap crossed over the other; Figure 20 is a bottom view of the folding hat of Figure 17, in an erected condition; 20 Figure 21 is a top view of the folding hat of Figure 17, in an erected condition; Figure 22 is a rear view of the folding hat of Figure 17, in an erected condition; Figure 23 is a perspective view of a folding hat according to a ninth aspect of the invention, in an erected condition; 10 Figure 24 is a blank for the folding hat of Figure 23; Figure 25 is a side view of the folding hat of Figure 23, assembled and in a folded condition according to a first embodiment; Figure 26 is a side view of the folding hat of Figure 23, assembled and in a folded 5 condition according to a second embodiment; Figure 27 is a bottom view of the folding hat of Figure 23, in an erected condition; Figure 28 is a side view of the folding hat of Figure 23, in an erected condition; and Figure 29 is a front view of the folding hat of Figure 23, in an erected condition. 10 Detailed description of the embodiments Description of the embodiment illustrated in Figures 1 through 16 Referring to Figure 1 of the drawings, there is shown a folding hat 10 formed from paper sheet material, including a crown 12 and a brim 14. The brim 14 has an outer edge 16 and an inner edge 18, of oval shape, the inner edge 18 sitting around the lower 15 edge 20 of the crown 12, with the upper surface 22 projecting outwards from the crown walls 24. The crown walls 24 extend upwardly from the lower edge 20 tapering inwardly up the height of the walls 24. The crown has a front seam 26 and a rear seam 28, with the top of the walls 24 ending in a crease line 30 that curves downwardly at a midpoint between the front seam 20 26 and the rear seam 28. The lower edge 20 of the crown is correspondingly curved, such that when erected an oval shape is formed. It will be appreciated that the lower edge of the crown may be straight. The upper portion 32 of the crown has a central crease line 34 that is a straight line between the front seam 26 and the rear seam 28. The brim 14 has corresponding crease lines 36 that extend in line with the central 25 crease line 34 from the inner edge 18 to the outer edge 16. To enable folding of the hat 10 into a substantially flat condition, the whole hat 10 cannot simply be folded in half, as the inner circumference of the brim 14 matches the 11 outer circumference of the crown 12. Due to the curve of the lower edge 20 and the oval shape, when folded flat the width A of the crown 12 between the front seam 26 and the rear seam 28 at the lower edge 20 is greater than the width C between the crease lines 36 at the inner edge 18. Therefore, to fold the hat 10 flat, whilst the brim 14 is attached 5 to the crown 12 without pleating the brim, the brim 14 must move from this first configuration to a second configuration. By sliding the brim 14 up the walls 24 the brim 14 will reach a second configuration when the width C is greater than a width B, being a second distance between the front seam 26 and the rear seam 28 at some point along the height of the walls 24. 10 To facilitate the moveable connection between the crown 12 and the brim 14, a sliding arrangement is provided. Best illustrated in the blank of the crown 12 shown in Figure 2, on each side wall 24 two spaced apart slots 38 are provided extending a proportion of the height of the side walls 24 between the lower edge 20 and the crease line 30. Extending from the inner edge 18 of the brim 14 at two opposing sides are 15 central projections 40, each with outwardly extending arms 42 that fold at crease lines 44 at the sides of the central projection 40. The arms 42 include opposing notches 46, 48, such that when the arms 42 are inserted through respective slots 38 the arms 42 are folded along crease lines 44 back across the central projection 40, around the central strip 50 that extends between the two slots 38. The ends of the arms 42 are 20 overlapped and the opposing notches 46, 48 slot into one another, securing the arms about the central strip 50. When forming the hat 10 from the blanks shown in Figures 2 and 3, the crown 12 is folded along central crease line 34, with seam edges 52a aligning with seam edges 52b, such that they are glued or otherwise fastened to create front seam 26 and rear 25 seam 28. The brim 14 is then folded along crease lines 36 and slid downwards around the outside of the crown 12 until the arms 42 align with slots 38, as shown in Figure 4. The arms 42 are then inserted through the slots 38 and the notches 46, 48 connected, as seen in Figure 6. The brim 14 is then free to slide up and down the slots when the crown is opened. To engage the brim 14 in the first erected configuration, inner 30 projections 54 aligned with crease lines 36 are locked into slits 56 provided along the front and rear seams 26, 28 of the crown. To disengage the slits 56 to enable folding, 12 the brim 14 must be pulled outwardly away from the crown 12 pulling the projections 54 out from the slits. When erecting the hat 10 from the folded condition, as it would be delivered to the wearer, the brim 14 simply needs to be slid down the slots 38 as the crown is 5 opened. Once the brim 14 reaches the bottom of the slots 38, the projections 54 are inserted into the slits 56 and the central crease line 34 is pushed downwardly, indenting the upper portion of the crown, this indented upper portion holds the structure of the crown and the walls 24 apart. Such a configuration gives the hat an appearance analogous to a slouch hat or cowboy hat. 10 An alternative embodiment of this folding hat arrangement is shown in Figures 9 through 16, which illustrate a folding hat 10 that forms a shape similar to a wizard or witches hat. In this embodiment, all aspects of construction of the brim 14 are the same as described above. Referring to Figure 10, the crown is created from a pie shaped sheet, having two seam edges 52c, 52d and one semi-circular lower edge 20. A 15 centralised crease line 58 is provided between the two seam edges such that when the seam edges 52c, 52d are joined they are directly opposite the crease line 58, on the inside of the hat. A peak or point 60 is created with the crown 12 taking a conical shape. Fold lines 62 are provided along the height of the crown, such that when moved into the second folded configuration, as shown in Figure 12, the crown can be folded over to 20 create a smaller overall size for transport. The advantage of having a brim that is moveable connected to the crown such that it can move between a first configuration whereby the hat cannot be easily folded and maintains its shape and a second configuration whereby the hat is able to be folded to substantially flat is that the brim does not need to include pleated sections to allow for 25 folding. The pleated sections create weakened portions of the brim, which potentially compromises the stiffness of the brim in creating a clean curved structure. Description of the embodiment illustrated in Figures 17 through 22 Figure 17 shows a folding hat 110 that is constructed to form a shape analogous to a baseball cap. The hat 100 includes a crown 112 and a peak or bill 114.

13 Turning to Figure 19, the blanks for forming the crown 112 and peak 114 are shown. The peak 114 is an arc having a curved outer edge 116, straight inner edges 118 forming a front portion 120 and rear portions 122. The front portion 120 includes a central fold line 124 and the rear portions 122 include apertures 126. At the centre of 5 the two inner edges 118 is a projecting tab 128. The peak 114 may also include a removable coupon 130. The crown 112 is made from two generally similarly hour glass shaped flaps 132, 134. The flaps each have a narrower central region 136 with wider lower ends 138a, 138b, 138c, 138d. At one end 138b, 138d of the flaps, the flaps 132, 134 are joined, 10 preferably being made from an integral sheet, otherwise being made from two pieces joined together. A crease line 140 is provided. At the outer corners of the flaps at ends 138b, 138d are apertures 142b, 142d. At the opposite ends 138a, 138c, apertures 142a, 142c are provided on the inner corners of the flaps. Near the outer corners at this end are slits 144 and seam edges 15 146. The second flap 134 also includes a series of tabs 148 projecting outwardly from the edge. A crease line 150 is also provided across the central region 136 of each flap 132, 134, extending in a diagonal manner. Aside from the tables 148, the two flaps are mirror images about crease line 140. To create the structure of the crown 112, flap 132 is folded across flap 134, as 20 shown in Figure 19A. As the flaps are overlapped they bend in the central region 136, allowing the seam edges 146 to meet. The seam edges 146 are joined together, creating front seam 152. The flattened shape created is much like that illustrated in Figure 18 without the peak attached. Either before or after the seam 152 is formed, a central pivot pin 154 is inserted into the centre of the two central regions 136. The pivot 25 pin 154 allows the two flaps to rotate with respect to each other, such that the flaps 132, 134 can be positioned to sit the flaps generally perpendicular to each other whereby aperture 142b can meet with aperture 142c and aperture 142d can meet with aperture 142a, the lower edges 156 creating a substantially square or diamond shape, best shown in Figure 20.

14 The peak 114 is attached to the crown 112 by aligning the apertures 126 on the end regions 122 of the peak with the aligned apertures 142b, 142c and 142d, 142a. Pivoting pins 158 are then inserted through the three aligned apertures 142b, 142c, 126 on a first side and 142d, 142a, 126 on a second side. 5 In the folded configuration, as shown in Figure 18, the crease 124 of the peak aligns with the crease lines 150 of the crown and with the front seam 152 and the rear crease line 140. To move from the flat folded configuration shown in Figure 18 to the erected configuration, as shown in Figures 17 and 20 through 22, the two sides of the crown 10 112 are pulled apart while the central regions 136 are pushed downwardly slightly at the central pivot pin 154 such that the flaps 132, 134 are able to rotate with the flaps moving apart from each other in the areas where they overlap to form the diamond shaped structure. To assist in holding this structure, additional crease lines 160 may be provided. The tabs 148 are provided to close the gap between the overlapping flaps, 15 however they may be optionally secured to the underside of the edges of flap 132. The projection 128 on the peak is slotted into slit 144 created on seam 152, as shown in Figure 18. The advantage of this folding hat configuration is that it can resemble a known baseball cap look, whilst being able to fold flat whilst the peak is attached to the crown 20 and readily reconfigured to an erect condition. Description of the embodiment illustrated in Figures 23 through 29 A folding hat 210 is shown in Figure 23 of a shape analogous to the hat commonly referred to as a bucket hat. Such bucket hats 210 have a crown 212 with slightly inwardly tapered walls 214 and a narrow brim 216 having a curved outer edge 25 218. The top edges 220 of the walls 214 are typically straight, with the walls 214 being joined at two side seams 222, by joining seam edges 226 together. The lower edge 224 of the walls 214 has a curve corresponding to the curve of the outer edge 218. Attached to the crown side walls 214 may be removable coupons 228, which are typically hidden inside the hat 210 when constructed.

15 The two walls 214 are joined at their top edges 220 by a central portion 230. The central portion 230 comprises a middle region 232, being the shape of two trapezoids joined along their shorter length at a central crease line 234, which folds in a first direction, being upwardly away from the top edges 220. The trapezoids are joined along 5 their longer length to the top edges 220. Extending out from the sides of the middle region 232 are outer sections 236, having an outer edge 238 shaped like a pointed or equilateral arch. This pointed arch corresponds to the internal shape of the crown when erected. Alternatively, the outer sections 236 may be rounded arches. The outer sections 236 meet the middle region 232 at crease lines 240, which 10 preferably fold upwardly with the central crease line 234. The outer sections 236 include central crease lines 242, which fold in the opposite direction to the crease lines 240 and 234, such that the outer sections 236 fold inwardly under the middle region 232. This is shown in Figure 26. An alternative, shorter walled bucket hat is shown in Figure 25, whereby the central portion 230 is constructed in a similar way, but the crease line 234 15 is able to fold in a downward direction also, such that when in the folded configuration it folds down and in the erected configuration it folds upwards. The various embodiments of the present invention provide folding hats that may be reconfigured from a folding condition to an erected condition and back again, whilst the brim or peak is affixed to the crown. The folding hats may be constructed from sheet 20 material at one location, folded flat and transported efficiently and cheaply to a second location, where they can be easily erected by the end user or by a person as they are handed out to end users. The end user can then easily fold the hat for storage and use again or discarded due to the material being of a recyclable nature i.e. paper. It will be understood that the invention disclosed and defined in this specification 25 extends to all alternative combinations of two or more of the individual features mentioned or evident from the text or drawings. All of these different combinations constitute various alternative aspects of the invention.

Claims (9)

1. A folding hat formed from sheet material, including: a crown and a brim connected such that the brim is moveable relative to the 5 crown between a first configuration whereby the hat is in an erected condition and a second configuration whereby the hat is able to be folded substantially flat.

2. A method of forming a hat, including the steps of: forming a brim from a first sheet portion, the brim including loop means; 10 forming a crown from a second sheet portion, the crown including at least one set of slots extending in a direction of the height of the crown; attaching the brim to the crown by positioning the loop means through the slots and securing in place; wherein the brim is connected to the crown in a sliding arrangement such that the 15 brim is moveable relative to the crown between a first configuration whereby the hat is in an erected condition and a second configuration whereby the hat is able to be folded substantially flat.

3. A method of assembling a hat according to claim 1 from a sheet to a flat 20 deconstructed hat, the method including the steps of: forming the brim from a first sheet portion; forming the crown from a second sheet portion; connecting the brim to the crown in a sliding arrangement such that the brim is moveable relative to the crown between a first configuration whereby the hat is in 25 an erected condition and a second configuration whereby the hat is able to be folded substantially flat. 17

4. A method of erecting a hat according to claim 1 from a flat condition to an erect condition, the method including the steps of: moving the brim from the second configuration to the first configuration by sliding the brim downwards with respect to the crown and opening the crown.

5 5. A folding hat formed from sheet material, including: a crown and a peak attached to the crown, whereby the crown is formed from two flaps that are positioned to overlap and fasten together at a central region such that the two flaps can rotate with respect to each other to move between a first configuration to form the structure of the crown, opening the peak and a second 10 configuration to enable the crown and peak to fold flat.

6. A method of forming a hat, including the steps of: forming a crown from sheet material including two overlapping flaps and securing them at a central region such that they are able to rotate with respect to each other; 15 forming a peak from sheet material, the peak having two rear points; fastening two flaps together at their respective lower ends, with the rear points of the peak attaching to lowers ends of one or more flaps; whereby the two flaps can rotate with respect to each other to move between a first configuration to form the structure of the crown, opening the peak to a 20 second configuration to enable the crown and peak to fold flat.

7. A method of assembling a hat according to claim 5 from a sheet to a flat deconstructed hat, the method including the steps of: forming a crown from sheet material including two overlapping flaps and securing them at a central region such that they are able to rotate with respect to each 25 other; forming a peak from sheet material, the peak having two rear points; 18 fastening two flaps together at their respective lower ends, with the rear points of the peak attaching to lowers ends of one or more flaps; rotating the two flaps with respect to each other to move from a first configuration to form the structure of the crown to a second configuration folding the crown and 5 peak flat.

8. A method of erecting a hat according to claim 5 from a flat condition to an erect condition, the method including the steps of: spreading slightly the lower ends of the flaps, pushing downwardly on the central region of the crown and rotating the two flaps with respect to each other to form 10 the structure of the crown.

9. A folding hat formed from a single piece of sheet material, including: a first side and a second side being joined together by a central portion, each of the sides including a crown portion and a brim portion integrally formed, the edges of the first side joining to respective edges of the second side; 15 the central portion having a middle section connected to the first and second sides and outer sections not connected to the first and second sides; whereby the middle section has a central fold line in a first direction and the outer sections have at least one fold line in a second direction, such that when folded, the outer sections fold inwardly under the middle section.