WO2004026060A2

WO2004026060A2 - Molded headgear

Info

Publication number: WO2004026060A2
Application number: PCT/US2003/025217
Authority: WO
Inventors: Bryant Shapiro
Original assignee: Bryant Shapiro
Priority date: 2002-09-17
Filing date: 2003-08-13
Publication date: 2004-04-01
Also published as: AU2003259780A8; WO2004026060A3; AU2003259780A1

Abstract

A molded headgear (50) formed from a laminated combination of a first, outer layer (60), a second, central layer (70) and a third, inner layer (80) of material relative to a wearer, said laminated combination being molded into a first shape (90) adapted to conform to a human head. The molded headgear (50) is flexible, pliable, bendable and resilient and springs back to its original shape once folded and released.

Description

MOLDED HEADGEAR

CROSS REFERENCE TO RELATED APPLICATION This application claims the benefit of U.S. Provisional Application 60/411,380 filed September 17, 2002. FIELD OF THE INVENTION

This invention relates to a molded headgear such as, by way of example, a skull cap (Yarmulke). The headgear is formed as a single molded piece and is flexible, pliable, bendable and resilient so that it can be folded and stored in one's pocket.

BACKGROUND OF THE INVENTION While heretofore it has been known to form molded headgear in general, such known headgear would not be usable for items such as skull cap, which requires that it be foldable so that it can be inserted into a pocket and stored. By way of example, U.S. Pat. 6,401,258 describes a molded foam helmet that can be used by fans in support of a football team. However, since it is to emulate a helmet, it is rather stiff and not suitable for folding into a pocket. U.S. Pat. 3,725,956 discloses a helmet formed of a fabric with an intermediate layer of foam plastic and an underlying lining of cotton. However, such molded helmet is still and also unsuitable for folding in one's pocket.

The use of molding techniques are also well known from U.S. Pat. 2,112,384 and U.S. Pat. 6,021,931. However, such disclosed molding techniques use other materials for molding than are contemplated in the present invention. Likewise, the use of foam itself is shown in U.S. Pat. D410.134.

However, such prior art molded headgear are not suitable for use in connection with a molded skull cap that would be flexible, pliable, bendable and resilient so that it can be folded into a pocket and springs back into shape once removed from one's pocket. SUMMARY OF THE INVENTION

A molded headgear formed from a laminated combination of a first, outer layer, a second, central layer and a third, inner layer of material, said laminated combination being molded into a first shape that is adapted to conform to a human head. The molded headgear is flexible, pliable and bendable and has shape memory and resiliency so that it can be folded from such first shape into a second shape and stored in one's pocket, and wherein said molded headgear assumes said first shape when removed from one's pocket and released from a folded condition.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a cross-sectional view of a molded headgear of the present invention taken through line 1-1 of FIG. 3.

FIG. 2 illustrates the manufacturing of a molded headgear from a laminated combination of fabrics. FIG. 3 is a bottom view of the molded headgear of FIG. 1.

FIG. 4 is an edge view of the molded headgear of FIG. 1 folded in half. FIG. 5 is an edge view of the molded headgear of FIG. 1 folded in quarters.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT The following detailed description is of the best mode or modes of the. invention presently contemplated. Such description is not intended to be understood in a limiting sense, but to be an example of the invention presented solely for illustration thereof, and by reference to which in connection with the following description and the accompanying drawings one skilled in the art may be advised of the advantages and construction of the invention. In the various views of the drawings, like reference characters designate like or similar parts.

Figure 1 is an edge view of a molded headgear 50 of the present invention formed from a laminated combination of a first, outer layer 60, a second, central layer 70 and a third, inner layer 80 of material, said layers 60, 70, 80 being defined relative to the wearer, said laminated combination being molded into a first shape 90 adapted to conform to a human head. The central layer or filler portion 70 is preferably made of 100% foam. By way of example, a typical foam that could be utilized for such purpose has the following specifications.

Material: Polyester Foam Density: 1.30 lbs/cu. Ft. Tensile Average: 28 psi

Ultimate Elongation: 300% Tear Resistance: 3.00 ppi

Compression Set: 6% - 50% deflection Cell Count (Visual) 60 + or - 5/inch Test Methods: ASTM D-3574

It should be appreciated, that other foams may be used in the manufacture of the molded headgear of the present invention. While a polyester foam is preferred, polyurethane foam is an acceptable replacement. Other foams may also be used with equal success. These types of foam filler are currently used in the swimwear industry to produce molded bra cups for added support in some woman's bathing suits. The thickness can vary depending upon the desired results to be obtained. A thinner foam would result in a thinner, more flimsy product, while a thicker, denser foam would result in a more substantial feel to the wearer. However, using a foam of the type described and detailed above would provide the flexibility and resiliency needed for the headgear of the present invention.

The first, outer layer 60 of the molded headgear 50 is preferably made of a Nylon/Lycra Spandex or a Polyester/Lycra Spandex fabric. By way of example such are essentially five to six ounce weight fabric of approximately fifty-eight inch width. The fiber content can also vary, but generally would be in the range of about eighty-five percent Nylon or Polyester, fifteen percent Lycra/Spandex. However, it should be appreciated that the fabric itself can be also of varying weight and finishes, depending on the desired results to be obtained. For instance, stretch fabrics can be made to have the appearance of suede, velvet, shinny or dull finishes, ribbed, printed with various designs, etc.

The third, inner layer 80, or underside (relative to the wearer) of the molded headgear 50, could also be made of the same Nylon/Lycra Spandex or Polyester/Lycra Spandex fabric as the first, outer (relative to the wearer) layer 60, for those styles that would be made to be reversible. For those headgear 50 not made to be reversible, one could utilize a simple 100%o nylon tricot, 100% polyester, or even a blend of cotton/Lycra Spandex to form such inner layer 80. Any of the fabrics mentioned above would lend themselves to imprinting after production where it is desired to personalize the headgear to remember a particular occasion, such as wedding, Bar Mitzvah, convention, etc.

Figure 2 illustrates an edge view of the basic combination of construction layers 60, 70, 80 prior to laminating and molding, such combination starting as a flat shape 100 as shown. A metal mold having a top piece 110 and a bottom piece 120 with a basic semi- spherical shape 130 is preferably used to form the molded headgear 50 and to ensure the consistency of the basic headgear shape 90 (Figure 1). Of course, other molds having different shapes may be used, depending on the desired results to be obtained. For instance, there may be smaller sizes for children or larger sizes to suit individual tastes. For different headgear styles, variations could be made within the mold itself. For example, a semi- spherical type mold could be provided with a design 140, which may be done as a raised or recessed shape. One such design might be a Star of David as shown in Figure 2, that would become imprinted onto the inner layer 80 of the molded headgear 50. Once the laminated combination 100 is placed between the top piece 110 and bottom piece 120 of the mold, such pieces 110, 120 are compressed together with the laminated combination 100 situated therebetween. Through the use of heat, pressure, and dwell time, the laminated combination is thereby compressed into the basic headgear shape 90 as shown in Figure 1. Thereafter, the headgear piece 50 is cut from the laminated combination using a metal die 150, 160 or the like. It is estimated that, given a basic width of fifty-five to fifty-eight inches of the laminated combination of layers 60, 70, 80, between thirty-five to forty headgear units 50 can be produced.

After the basic molded headgear 50 has been produced, such molded headgear 50 may be sent to another manufacturing area for additional finishing, such as edging 170 (Figure 3) with soutache cording, embroidery, screen printing, etc. The headgear 50 may also have an imprinting 180 on the underside (relative to the wearer) layer 80 to memorialize a special event. If used as a skull cap, it would not weigh anymore than an average crocheted or suede skull cap, and would also not absorb perspiration any more than a skull cap presently being utilized. Furthermore, additional benefits in producing a molded headgear 50 in this matter would be as follows: a. The headgear 50 has "memory" and springs back to shape even when compressed in half (FIG. 4) or in quarters (FIG. 5) and stored in a pocket, and would not crease like the more conventional types. b. The headgear 50 would be hand washable with mild detergent, and retain its color and shape despite washing. c. A headgear 50 made using the method of the present invention could also be manufactured to be reversible. For example, the outer layer 60 could be a blue velvet-like fabric, while the inner layer 80 could be a gray suede-like fabric. d. Depending on the type of mold 110, 120 used, designs, logos, emblems, etc. 140 could be impressed into the fabric of either outer or inner layer 60, 80 during the molding process, which would enhance the product, and increase marketability.

While the present invention has been described at some length and with some particularity with respect to the several described embodiments, it is not intended that it should be limited to any such particulars or embodiments or any particular embodiment, but it is to be construed with references to the appended claims so as to provide the broadest possible interpretation of such claims in view of the prior art and, therefore, to effectively encompass the intended scope of the invention. Furthermore, the foregoing describes the invention in terms of embodiments foreseen by the inventor for which an enabling description was available, notwithstanding that insubstantial modifications of the invention, not presently foreseen, may nonetheless represent equivalents thereto.

Claims

CLAIMSI claim:

1. A molded headgear comprising: a) a laminated combination of a first, outer layer, a second, central layer and a third, inner layer of material, b) said laminated combination being molded into a first shape adapted to conform to a human head, c) said molded headgear being flexible, pliable and bendable, d) said molded headgear having shape memory and being resilient so that it can be folded from a first shape at rest into a second shape and stored in one's pocket in said second shape, and e) wherein said molded headgear assumes said first shape when removed from one's pocket and released from a folded condition.

2. A molded headgear in accordance with claim 1, wherein said second layer is foam.

3. A molded headgear in accordance with claim 2, wherein said foam is a polyester foam with a density of approximately 1.30 pounds per cubic foot.

4. A molded headgear in accordance with claim 3, wherein said foam has a tensile average of twenty-eight pounds per square inch.

5. A molded headgear in accordance with claim 4, wherein said foam has a tear resistance of three parts per inch.

6. A molded headgear in accordance with claim 1, further comprising one of an insignia, design, logo or emblem provided on one of said first or third layers of material.

7. A molded headgear in accordance with claim 1, further comprising an occasion stamp provided on one of said first or third layers of material.

8. A method of manufacturing a molded headgear comprising the steps of: a) laminating a combination of a first, outer layer, a second, central layer and a third, inner layer of material, and b) compression molding said laminated combination into a molded headgear having a first shape adapted to conform to a human head, c) wherein said molded headgear is flexible, pliable and bendable, and d) wherein said molded headgear has shape memory and is resilient so that it can be folded from a first shape at rest into a second shape and stored in one's pocket in said second shape, and wherein said molded headgear assumes said first shape when removed from one's pocket and released from a folded condition.

9. A method in accordance with claim 8, wherein said second layer is foam.

10. A method in accordance with claim 9, wherein said foam is a polyester foam with a density of approximately 1.30 pounds per cubic foot.

11. A method in accordance with claim 10, wherein said foam has a tensile average of twenty-eight pounds per square inch.

12. A method in accordance with claim 11, wherein said foam has a tear resistance of three parts per inch.

13. A method in accordance with claim 8, further comprising the step of providing one of an insignia, design, logo or emblem on one of said first or third layers of material.

14. A method in accordance with claim 8, further comprising the step of providing an occasion stamp on one of said first or third layers of material.