U.S. patent application number 13/880414 was filed with the patent office on 2013-08-15 for folding hat.
This patent application is currently assigned to PUNCH FOLD TUCK PTY LTD. The applicant listed for this patent is Michael Chijoff, Carl Thornton Jones, Franco Schena. Invention is credited to Michael Chijoff, Carl Thornton Jones, Franco Schena.
Application Number | 20130205475 13/880414 |
Document ID | / |
Family ID | 45974555 |
Filed Date | 2013-08-15 |
United States Patent
Application |
20130205475 |
Kind Code |
A1 |
Jones; Carl Thornton ; et
al. |
August 15, 2013 |
FOLDING HAT
Abstract
A folding hat formed from sheet material, including a crown and
a brim, wherein the brim is attached to the crown, and a bottom rim
portion of the crown imparts shaping to the brim. In one form, an
upper surface of the crown is indented, and the bottom rim portion
of the crown supports the brim in a generally continuous curve
whereby an upper surface of the brim is curved from one edge of the
brim to an opposite edge of the brim.
Inventors: |
Jones; Carl Thornton;
(Pascoe Vale South, AU) ; Chijoff; Michael;
(Flemington, AU) ; Schena; Franco; (Berwick,
AU) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Jones; Carl Thornton
Chijoff; Michael
Schena; Franco |
Pascoe Vale South
Flemington
Berwick |
|
AU
AU
AU |
|
|
Assignee: |
PUNCH FOLD TUCK PTY LTD
Footscray, Victoria
AU
|
Family ID: |
45974555 |
Appl. No.: |
13/880414 |
Filed: |
October 20, 2011 |
PCT Filed: |
October 20, 2011 |
PCT NO: |
PCT/AU11/01335 |
371 Date: |
April 19, 2013 |
Current U.S.
Class: |
2/209.13 ;
2/175.1 |
Current CPC
Class: |
A42B 1/201 20130101;
A42B 1/208 20130101 |
Class at
Publication: |
2/209.13 ;
2/175.1 |
International
Class: |
A42B 1/20 20060101
A42B001/20 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 20, 2010 |
AU |
2010904685 |
Claims
1. A folding hat formed from sheet material, including a crown and
a brim, wherein the brim is attached to the crown, and a bottom rim
portion of the crown imparts shaping to the brim.
2. A folding hat as claimed in claim 1, wherein an upper surface of
the crown is indented.
3. A folding hat as claimed in claim 1, wherein the bottom rim
portion of the crown supports the brim in a generally continuous
curve whereby an upper surface of the brim is curved from one edge
of the brim to an opposite edge of the brim.
4. A folding hat as claimed in claim 3, wherein the upper surface
of the brim is convexly curved from one edge of the brim to an
opposite edge of the brim.
5. A folding hat as claimed in claim 4, wherein the upper surface
of the brim is convexly curved from a front edge of the brim to a
rear edge of the brim.
6. A folding hat as claimed in claim 1, wherein the hat is held
together entirely by folding said sheet material.
7. A folding hat as claimed in claim 1, wherein the brim is
attached to the crown by a plurality of tabs formed in one of the
brim or crown, said tabs interlocking with slots formed in the
other of the brim or crown.
8. A folding hat as claimed in claim 7, wherein the crown is folded
at the bottom rim portion, with said slots formed at or near said
fold, and wherein said tabs are formed at an inside edge of the
brim.
9. A folding hat as claimed in claim 1, wherein the sheet material
is printed on only one side, and the hat is arranged such that all
surface of the hat visible from above the head of a wearer are
printed.
10. A folding hat as claimed in claim 1, wherein the hat has a
detachable coupon, the coupon being adapted such that it can be
removed from the hat without affecting the appearance of the hat
when worn.
11. A folding hat as claimed in claim 1, wherein the sheet material
is paper.
12. A folding hat formed from sheet material, including a crown and
a brim, wherein the brim is attached to the crown, and the hat is
adapted to be folded between a flat condition and an erect
condition.
13. A folding hat as claimed in claim 12, wherein the brim is
attached to the crown in both the flat condition and the erect
condition.
14. A folding hat as claimed in claim 12, wherein in the flat
condition the hat is fully flat to accommodate flat stacking of a
plurality of like folding hats.
15. A folding hat as claimed in claim 12, wherein the brim has
transverse folds across the brim, the transverse folds being folded
in the flat condition so as to layer portions of the brim, and the
transverse folds being unfolded in the erect condition.
16. A folding hat as claimed in claim 15, wherein when in the flat
condition the transverse folds are folded such that a section of an
upper surface of the brim is folded onto itself.
17. A folding hat as claimed in claim 16, wherein the transverse
folds diverge toward an outer edge of the brim.
18. A folding hat as claimed in claim 12, wherein the crown has an
upper portion which, when in the erect condition, is indented to
form a concave top surface providing lateral structure to the
crown, and, when in the flat condition, is folded along a central
fold running centrally of the upper portion.
19. A folding hat as claimed in claim 15, wherein, when in the
erect condition, the brim is curled across the transverse folds to
maintain the transverse folds in an unfolded state.
20. A method of forming a hat, including the steps of: forming a
brim from a first sheet portion; forming a crown from a second
sheet portion; attaching the brim to the crown; and indenting an
upper surface of the crown, wherein the hat is configured such that
a bottom rim portion of the crown supports the brim in a curve
whereby an upper surface of the brim is convexly curved.
21. A method of forming a hat as claimed in claim 20, wherein the
bottom rim portion of the crown supports the brim in a curve
whereby an upper surface of the brim is convexly curved from one
edge of the brim to an opposite edge of the brim.
22. A folding hat formed from sheet material, wherein the hat has a
detachable coupon, the coupon being adapted such that it can be
removed from the hat without affecting the appearance of the hat
when worn.
23. A method of assembling a hat from a sheet to a flat
deconstructed hat, the hat being a hat as claimed in claim 12, the
method including the steps of: forming the brim from a first sheet
portion; forming the crown from a second sheet portion; and
attaching the brim to the crown; wherein transverse folds of the
brim are folded such that a surface of the brim is folded onto
itself to layer portions of the brim.
24. A method of erecting a hat from a flat condition to an erect
condition, the hat being a hat as claimed in claim 12, the method
including the steps of: indenting an upper surface of the crown;
unfolding transverse folds of the brim; and curling the brim across
the transverse folds to maintain the transverse folds in an
unfolded state.
25. (canceled)
26. (canceled)
Description
FIELD OF THE INVENTION
[0001] The invention relates to a folding hat, and more
particularly, but not exclusively, to a hat folded from a sheet of
paper.
BACKGROUND OF THE INVENTION
[0002] It is known to provide hats constructed from paper sheeting.
For example, U.S. Pat. No. 4,429,420 discloses a cowboy hat formed
from a single sheet of paper-board which is cut and scored.
However, the applicant has determined that it would be beneficial
to provide a folding hat with an improved construction method which
allows easy assembly and disassembly, and/or providing improved
shaping to the hat. In addition, the applicant has determined that
the folding hat may maximise space for branding/promotion, and/or
may have a uniquely cultural flavour (eg, 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.
[0003] Examples of the present invention seek to provide a folding
hat formed from sheet material which overcomes or at least
alleviates one or more disadvantages associated with previous paper
hats.
SUMMARY OF THE INVENTION
[0004] In accordance with one aspect of the present invention,
there is provided a folding hat formed from sheet material,
including a crown and a brim, wherein the brim is attached to the
crown, an upper surface of the crown is indented, and a bottom rim
portion of the crown imparts shaping to the brim.
[0005] Preferably, the bottom rim portion of the crown supports the
brim in a generally continuous curve whereby an upper surface of
the brim is curved from one edge of the brim to an opposite edge of
the brim.
[0006] Preferably, the upper surface of the brim is convexly curved
from one edge of the brim to an opposite edge of the brim. More
preferably, the upper surface of the brim is convexly curved from a
front edge of the brim to a rear edge of the brim.
[0007] Preferably, the hat is held together entirely by folding
said sheet material.
[0008] Preferably, the brim is attached to the crown by a plurality
of tabs formed in one of the brim or crown, said tabs interlocking
with slots formed in the other of the brim or crown. More
preferably, the crown is folded at the bottom rim portion, with
said slots formed at or near said fold, and wherein said tabs are
formed at an inside edge of the brim.
[0009] In one form, the sheet material is printed on only one side,
and the hat is arranged such that all surfaces of the hat visible
from above the head of a wearer are printed.
[0010] In a preferred example, the hat has a detachable coupon, the
coupon being adapted such that it can be removed from the hat
without affecting the appearance of the hat when worn.
[0011] It is preferred that the sheet material is paper.
[0012] In accordance with another aspect of the present invention,
there is provided a folding hat formed from sheet material,
including a crown and a brim, wherein the brim is attached to the
crown, and the hat is adapted to be folded between a flat condition
and an erect condition.
[0013] Preferably, the brim is attached to the crown in both the
flat condition and the erect condition.
[0014] Preferably, in the flat condition, the hat is fully flat to
accommodate flat stacking of a plurality of like folding hats.
[0015] In a preferred form, the brim has transverse folds across
the brim, the transverse folds being folded in the flat condition
so as to layer portions of the brim, and the transverse folds being
unfolded in the erect condition. More preferably, when in the flat
condition the transverse folds are folded such that a section of an
upper surface of the brim is folded onto itself. Even more
preferably, the transverse folds diverge toward an outer edge of
the brim.
[0016] Preferably, the crown has an upper portion which, when in
the erect condition, is indented to form a concave top surface
providing lateral structure to the crown, and, when in the flat
condition, is folded along a central fold running centrally of the
upper portion.
[0017] Preferably, when in the erect condition, the brim is curled
across the transverse folds to maintain the transverse folds in an
unfolded state.
[0018] In accordance with another aspect of the present invention,
there is provided a method of forming a hat, including the steps
of: [0019] forming a brim from a first sheet portion; [0020]
forming a crown from a second sheet portion; [0021] attaching the
brim to the crown; and [0022] indenting an upper surface of the
crown, [0023] wherein the hat is configured such that a bottom rim
portion of the crown supports the brim in a curve whereby an upper
surface of the brim is convexly curved.
[0024] Preferably, the bottom rim portion of the crown supports the
brim in a curve whereby an upper surface of the brim is convexly
curved from one edge of the brim to an opposite edge of the
brim.
[0025] In accordance with another aspect of the present invention,
there is provided a folding hat formed from sheet material, wherein
the hat has a detachable coupon, the coupon being adapted such that
it can be removed from the hat without affecting the appearance of
the hat when worn.
[0026] In accordance with another aspect of the present invention,
there is provided a method of assembling a hat from a sheet to a
flat deconstructed hat, the hat being a hat as described above, the
method including the steps of: [0027] forming the brim from a first
sheet portion; [0028] forming the crown from a second sheet
portion; and [0029] attaching the brim to the crown; [0030] wherein
transverse folds of the brim are folded such that a surface of the
brim is folded onto itself to layer portions of the brim.
[0031] In accordance with another aspect of the present invention,
there is provided a method of erecting a hat from a flat condition
to an erect condition, the hat being a hat as described above, the
method including the steps of: [0032] indenting an upper surface of
the crown; [0033] unfolding transverse folds of the brim; and
[0034] curling the brim across the transverse folds to maintain the
transverse folds in an unfolded state.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] The invention is described, by way of non-limiting example
only, with reference to the accompanying drawings, in which:
[0036] FIG. 1 shows an upper/side perspective view of a folding hat
in accordance with an example of the present invention;
[0037] FIG. 2 shows a blank for forming the hat of FIG. 1;
[0038] FIG. 3 shows a top view of a brim of the hat of FIG. 1;
[0039] FIG. 4 shows a top view of the crown of the hat of FIG. 1,
shown in an unfolded condition;
[0040] FIG. 5 shows the crown in a partially folded condition;
[0041] FIG. 6 shows the crown in a further partially folded
condition;
[0042] FIG. 7 shows the crown in yet a further partially folded
condition;
[0043] FIG. 8 shows the brim being attached to the partially folded
crown;
[0044] FIG. 9 shows the completed hat;
[0045] FIGS. 10a and 10b show a folding hat in accordance with an
example of the present invention which includes a detachable
coupon;
[0046] FIG. 11 shows a side view of a folding hat in accordance
with another example of the present invention, the hat being
depicted in a flat condition;
[0047] FIG. 12 shows an underside of the hat of FIG. 11, the hat
being depicted in the flat condition;
[0048] FIG. 13 is a side view of the folding hat of FIGS. 11 and
12, shown in an intermediate condition;
[0049] FIG. 14 is a perspective view of the folding hat of FIGS. 11
to 13, the hat shown in a further intermediate condition;
[0050] FIG. 15 is a perspective view of the folding hat of FIGS. 11
to 14, the hat shown in an erect condition; and
[0051] FIG. 16 is an underside view of the folding hat of FIGS. 11
to 15, the hat shown in the erect condition.
DETAILED DESCRIPTION
[0052] With reference to FIG. 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 is attached to the crown 12, and a
bottom rim portion 16 of the crown 12 imparts shaping to the brim
14. More specifically, an upper surface 18 of the crown 12 is
indented, and the bottom rim portion 16 of the crown 12 supports
the brim 14 in a generally continuous curve 20 whereby an upper
surface 22 of the brim 14 is curved from one edge of the brim 14 to
an opposite edge of the brim 14.
[0053] Advantageously, in the example shown in FIG. 1 of the
drawings, the upper surface 22 of the brim 14 is convexly curved
from a front edge 24 of the rim 14 to the rear edge 26 of the brim
14. By virtue of the indentation in the upper surface 18 of the
crown 12 and the convex curve of the upper surface 22 of the brim
14, the folding hat 10 is given the shaping of an Australian
stockman hat. The applicant has identified that it would be
beneficial for a hat with shaping shown in the drawings to be
provided, as it would appeal to people attending events having an
Australian flavour, particularly with appeal to overseas visitors
to large Australian sporting events.
[0054] Although the example shown is in the form of an Australian
stockman hat, it will be appreciated that alternative examples of
the invention may take other forms, such as hats typical of other
countries/regions, including but not limited to the following hat
styles: Sombrero, Panama, Fedora, Havana, Cowboy and Slouch
hat.
[0055] FIGS. 2A and 2B show a blank for forming the folding hat 10.
More specifically, on the left-hand side of the drawing in FIG. 2A
is shown a blank for forming the crown 12, and on the right-hand
side of the drawing in FIG. 2B is shown a blank for forming the
brim 14. Although the brim 14 is initially in a flat configuration,
shaping is imparted to the brim 14 by the crown 12 during assembly
of the folding hat 10 such that the upper surface 22 of the brim 14
has a generally continuous convex curvature from the front edge 24
of the brim 14 to the rear edge 26 of the brim 14.
[0056] Advantageously, the hat 10 is held together entirely by
folding the sheet material, as is demonstrated by the assembly of
the folding hat 10 as shown progressively in FIGS. 3 to 9. By
virtue of folding hat 10 being held together entirely by folding,
adhesive and/or stitching is not required, and the folding hat 10
is therefore able to be assembled and disassembled easily and
inexpensively, without the need for purchasing adhesive or tools
required for stitching.
[0057] The brim 14 is attached to the crown 12 by a plurality of
tabs 28 formed in one of the brim 14 or the crown 12, the tabs 28
interlocking with slots 30 formed in the other of the brim 14 or
crown 12. In the particular example depicted in the drawings, the
crown 12 is folded at the bottom rim portion 16, with the slots 30
formed at or near the fold 32, the tabs 28 being formed at an
inside edge 34 of the brim 14.
[0058] Owing to the configuration of the folding hat 10, the sheet
material is able to be printed on only one side, as the hat 10 is
arranged such that all surfaces of the hat 10 visible from above
the head of a wearer are printed, even when only one side of the
sheet material is printed. This may be advantageous where it is
cost effective to print only one side of the sheet material, and
where it is not desirable to have the printed side of the material
in contact with the head of the wearer. In alternative examples,
branding and/or graphics may be printed on both sides of the sheet
of material. In other examples, the material may be printed on both
sides, as may be beneficial for particular hat styles where both
sides of the material are visible, including the slouch hat where
one side if the brim is pinned up to the crown, and certain styles
of cowboy hat where both sides of the brim are raised (and possible
also pinned up to the crown).
[0059] FIGS. 2A and 2B show locations at which the hat may be
provided with a detachable coupon 36, and preferably with a
plurality of detachable coupons 36. The coupons 36 are located such
that they can be removed from the hat 10 without affecting the
appearance of the hat 10 when worn. Advantageously, this is
achieved by locating the coupons 36 where the crown 12, when
folded, has a thickness of more than one layer of material so that
the coupon 36 can be removed for redemption by the wearer without
affecting the external appearance of the hat. Also, as the coupon
36 is removed from a portion adjacent the head of the wearer, the
underside appearance of the hat 10 is also not affected when the
hat 10 is worn. The hat 10 may be formed of paper material having
200 grams per square metre, however other grades of paper and other
sheet materials may also be used.
[0060] With reference to the assembly of the folding hat 10 as
shown in FIGS. 3 to 9 of the drawings, the crown 12 is folded in
half along its central axis 38 so as to form the partially folded
crown 12 as shown in FIG. 5. Subsequently, the crown 12 is folded
along the lines 40, in opposite directions, to arrive at the
configuration shown in FIG. 6. The lower edge is folded inwardly
along line 42. At this stage, the tabs 28 are able to be inserted
through the slots 30, as shown in FIG. 8, and a band 44 is formed
by folding upwardly at line 46 and downwardly at line 32.
Advantageously, the tabs 28 are locked in place as they are folded
downwardly along the inside of the band 44, and the band 44 also
serves to retain the folded triangles of the crown 12.
[0061] Once the tabs 28 are inserted into the slots 30 on both
sides of the crown 12, the crown is opened laterally to form the
cavity for receiving the head of the wearer, and the upper surface
18 of the crown 12 is indented by pressing downwardly so as to
support the opened crown 12. By virtue of the act of opening the
crown 12, the bottom rim portion 16 at either side becomes curved,
thereby imparting the convex shaping to the brim 14. The formed hat
10 is shown in FIG. 9.
[0062] FIGS. 10a and 10b show an example of the invention wherein
the coupon 36 is formed in an inside wall of the crown 12, with
dotted or perforated lines 50 along which the coupon 36 can be torn
out from the folded hat 10.
[0063] FIGS. 11 to 16 show a hat 10 in accordance with an
alternative example of the present invention. The hat 10 shown in
FIGS. 11 to 16 is generally similar to the one shown in FIGS. 1 to
10b, and like features are indicated with like reference numerals.
The main difference of the hat 10 shown in FIGS. 11 to 16 when
compared to the hat 10 shown in FIGS. 1 to 10b, is that the hat 10
shown in FIGS. 11 to 16 is adapted to be moved between a flat
condition and an erect condition, with the brim 14 attached to the
crown 12 in both conditions. More specifically, FIGS. 11 to 16 show
a folding hat 10 formed from sheet material, including a crown 12
and a brim 14. The brim 14 is attached to the crown 12, and the hat
10 is adapted to be folded between a flat condition (see FIGS. 11
and 12) and an erect condition (see FIGS. 15 and 16), via an
intermediate condition (see FIGS. 13 and 14).
[0064] The brim 14 is attached to the crown 12 in both the flat
condition and the erect condition. In the flat condition, the hat
10 is fully flat to accommodate flat stacking of a plurality of
like folding hats. This is advantageous as it enables a plurality
of the hats to be flat packed within a relatively small space,
which is beneficial for storage and transportation.
[0065] The brim 14 has transverse folds 52 across the brim 14, the
transverse folds 52 being folded in the flat condition so as to
layer portions 54 of the brim 14, and the transverse folds 52 being
unfolded in the erect condition. When in the flat condition, the
transverse folds 52 are folded such that a section of an upper
surface 22 of the brim 14 is folded onto itself. The transverse
folds 52 are generally radial/outward of the hat 10, at least when
the hat 10 is in the erect condition, and diverge toward an outside
edge of the brim 14. Pairs of the transverse folds 52 may intersect
at the inside edge of the brim 14.
[0066] The crown 12 has an upper portion which, when in the erect
condition, is indented to form a concave top surface 18 providing
lateral structure to the crown 12, and, when in the flat condition,
the surface 18 is folded along a central fold 54 running centrally
of the upper portion.
[0067] When in the erect condition, the brim 14 is curled across
the transverse folds 52 to maintain the transverse folds 52 in an
unfolded state. This curling may be assisted by the provision of a
plurality of parallel scores 56 which can be provided in a
direction which crosses the transverse folds 52.
[0068] The hat 10 shown in FIGS. 11 to 16 is able to be assembled
from a single sheet of paper into a flat packed condition, in which
condition it is delivered to the location at which it is provided
to the end user. The hat 10 is easily erectable from the flat
condition to the erect condition, and the erecting of the hat 10
may be done by either the distributors of the hats or by the end
users themselves. The method of forming a sheet of paper into a
flat deconstructed hat 10 includes the following steps: forming the
brim 14 from a first sheet portion; forming the crown 12 from a
second sheet portion; and attaching the brim 14 to the crown 12.
The transverse folds 52 of the brim 14 are folded such that a
surface of the brim 14 (ie. the upper surface or the lower surface
of the brim) is folded onto itself to layer portions of the brim
14. This method results in the hat 10 in the flat condition, as
shown in FIGS. 11 and 12.
[0069] The hat 10 is able to be readily moved between the flat
condition (shown in FIGS. 11 and 12) and the erect condition (shown
in FIGS. 15 and 16), via the intermediate condition shown in FIGS.
13 and 14. More specifically, the method of erecting the hat 10
from the flat condition to the erect condition, includes the steps
of: indenting the upper surface of the crown 12 (as is done in
bringing the hat 10 between the configurations shown in FIGS. 11
and 13); unfolding the transverse folds 52 of the brim 14 (as is
done in bringing the hat 10 between the configurations shown in
FIGS. 13 and 14); and curling the brim 14 across the transverse
folds 52 (as is done in bringing the hat 10 between the
configurations shown in FIGS. 14 and 15) to maintain the transverse
folds 52 in an unfolded state.
[0070] FIG. 15 also shows an instruction card 58 which may be
fitted to the band 44 of the crown 14, and may be inserted through
a slot also used for attaching the brim 14 to the crown 12. The
instruction card 58 may show instructions to instruct the end user
on how to erect the hat 10 from the flat condition to the erect
condition. The instructions may be summarised as "Open" (the crown
14), "Push" (the top of the crown 12 to indent it), "Roll" the brim
14 to curl the sides) and "Tear" (the instruction card 58 from the
hat 10).
[0071] FIG. 16 shows the underside of the hat 10 in the erect
condition and, in particular, the nature and location of the
detachable coupons 36 which are able to be removed from the hat 10
without affecting the appearance of the hat 10 when worn.
[0072] While various embodiments of the present invention have been
described above, it should be understood that they have been
presented by way of example only, and not by way of limitation. It
will be apparent to a person skilled in the relevant art that
various changes in form and detail can be made therein without
departing from the spirit and scope of the invention. Thus, the
present invention should not be limited by any of the above
described exemplary embodiments.
[0073] The reference in this specification to any prior publication
(or information derived from it), or to any matter which is known,
is not, and should not be taken as an acknowledgment or admission
or any form of suggestion that that prior publication (or
information derived from it) or known matter forms part of the
common general knowledge in the field of endeavour to which this
specification relates.
[0074] Throughout this specification and the claims which follow,
unless the context requires otherwise, the word "comprise", and
variations such as "comprises" and "comprising", will be understood
to imply the inclusion of a stated integer or step or group of
integers or steps but not the exclusion of any other integer or
step or group of integers or steps.
* * * * *