U.S. patent number RE29,452 [Application Number 05/537,792] was granted by the patent office on 1977-10-25 for headwear construction.
Invention is credited to Charles E. Townsend, Jr..
United States Patent |
RE29,452 |
Townsend, Jr. |
October 25, 1977 |
Headwear construction
Abstract
A headwear and a method of manufacturing headwear providing 95
percent or greater ventilation while at the same time providing
adequate shade protection are described. The headwear comprises a
crown section of cellular honeycomb, the cumulative cross-sectional
open cell area accounting for at least 90 percent of the total
surface area, contoured in such a manner as to provide a
progressive divergence of angularity between adjacent cells of the
honeycomb. The method comprises spirally winding together an
elongate flat strip and an elongate corrugated strip on a headwear
shaped form. The flat and corrugated strips are thus disposed in
alternating arrangement defining open cells therebetween to form a
cellular honeycomb contoured to the shape of the form.
Inventors: |
Townsend, Jr.; Charles E.
(Orinda, CA) |
Family
ID: |
26970001 |
Appl.
No.: |
05/537,792 |
Filed: |
December 30, 1974 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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89218 |
Nov 13, 1970 |
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Reissue of: |
297140 |
Oct 12, 1972 |
03811130 |
May 21, 1974 |
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Current U.S.
Class: |
2/209.7; 2/175.1;
2/200.3; 2/200.1; 2/195.1 |
Current CPC
Class: |
A42C
5/04 (20130101) |
Current International
Class: |
A42C
5/00 (20060101); A42C 5/04 (20060101); A42B
001/18 () |
Field of
Search: |
;2/177,175,195,198,3R,192,200 ;161/68 ;223/7,12 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Schroeder; Werner H.
Assistant Examiner: Nerbun; Peter
Attorney, Agent or Firm: Townsend and Townsend
Parent Case Text
This .Iadd.application is a reissue of Ser. No. 297,140, filed Oct.
12, 1972, now Pat. No. 3,811,130 which .Iaddend. is a
continuation-in-part of .[.my earlier.]. copending patent
application Ser. No. 89,218, filed Nov. 13, 1970, now abandoned.
Claims
What is claimed is: .[.
1. A headwear construction so adapted as to continually deflect
solar rays, yet provide maximum ventilation, comprising a
continuous crown section of open celled honeycomb material having a
compound curvature, each cell thereof hving a substantially equal
cross-sectional dimension, the axes of adjacent individual cells
diverging relative to one another to obliquely intersect said solar
rays over the majority of the total crown area at any given moment,
said open celled honeycomb material comprising a continuous
elongate flat strip and a continuous elongate corrugated strip
spirally wound together to form the continuous curved surface of
said crown..]. .[.2. The headwear according to claim 1 wherein each
of said axes are substantially perpendicular to that segment of the
wearer's skull to which they are respectively contiguous..]. .[.3.
The headwear according to claim 2, wherein the length of the side
walls of said honeycomb is at least equal to the nominal diameter
of the cells to limit the angle of transmittal of said cells, so
that said solar rays will be deflected at any given instant..].
.[.4. The headwear according to claim 3 wherein the angle of
transmittal .theta. of each said cell is less than about 45.degree.
as determined by the following equation: tan (90.degree. - .theta.)
= d/w, wherein w is the nominal diameter of said cells and d is the
thickness of said cells..]. .[.5. The headwear of claim 1 wherein
said open cell honeycomb material is contoured to define an
arcuately shaped crown..]. .[.6. The headwear covering of claim 5
wherein the cumulative cross-sectional area of the open cell areas
of the crown is at least about
90 percent..]. .[.7. The headwear of claim 1 wherein the thickness
of the honeycomb measured in the direction of the cell axes and the
nominal diameter of the cells are related to one another to limit
the angle of incidence through which direct overhead sunrays can be
transmitted through any given cell; the cumulative cross-sectional
open cell areas of the crown amounting to at least 90 percent of
the total surface area of the crown; the radius of curvature of the
arcuately contoured honeycomb section being sufficiently tight to
establish a progressive divergence of angularity between adjacent
cell axes whereby to limit direct sunray transmittal through the
crown to a minor fractional area thereof at any
given instant..]. .[.8. The headwear construction of claim 7
wherein the angle of incidence through which direct overhead
sunrays can be transmitted is limited to an angle not substantially
exceeding 45.degree...]. .[.9. The headwear of claim 7 so adapted
as to deflect solar rays yet provide maximum ventilation wherein
each cell of the honeycomb has a predetermined angle of sunlight
transmitted (.theta.), said angle being a function of the ratio of
cell thickness (d) to cell width (w) of each cell at its widest
space as follows:
d/w = tan (90.degree. - .theta.)", .theta.<45.degree...].
.Iadd.10. A headwear construction having a shaped crown comprising
an arcuately contoured section of cellular honeycomb having
compound curvature and disposed with the axes of its opened cells
extending radially therethrough; each cell of said honeycomb having
a substantially equal cross-sectional dimension; the thickness of
the honeycomb measured in the direction of the cell axes and the
nominal diameter of the cells being related to one another to limit
the angle of incidence through which overhead sunrays can be
transmitted through any given cell; the cumulative cross-sectional
open cell areas of the crown amounting to at least 90 percent of
the total surface area of the crown; the radius of curvature of the
arcuately contoured honeycomb section in each compound direction
being sufficiently tight to establish a progressive divergence of
angularity between adjacent cell axes in each said direction
whereby to limit direct sunray transmittal through the crown to a
minor fractional area thereof at any given instant..Iaddend.
Description
The present invention relates to improvements in headwear.
More particularly, the present invention relates to headwear
construction especially adapted for what might broadly be
classified as outdoor sports caps or hats such as used by golfers,
tennis players, boatsmen, sunbathers and outdoorsmen, where the
principal purpose of the head covering is to provide comfortable
shade protection for the head of the wearer. As will be seen, the
present invention may be utilized in the manufacture of caps having
sunshade visors. The headwear construction of the present invention
can also be utilized in the manufacture of hats having full brims,
the brim being either an integral part of the headpiece or formed
as a separate piece and attached thereto.
According to a first aspect of the present invention, there is
provided a form of head covering of the type having a shaped crown
and which comprises more specifically an arcuately contoured
section of cellular honeycomb which is so dimensioned, oriented and
arranged in combination as to optimally provide approximately 95
percent or greater ventilation through the crown while at the same
time providing adequate sunshade protection to the wearer's head
from the direct rays of the sun.
A feature of this invention is that the headpiece can be made to
fit so comfortably as to make the user virtually unaware of the
fact that he is wearing a protective head covering.
The honeycomb used in this construction may be made from any
non-absorbing material such as non-absorbent polyvinyl chloride,
polyethylene or other plastics, plastic impregnated papers or
fibers, and the like. The cellular honeycomb may even be
constructed from metals. By use of such non-absorbent material, the
need for providing absorbent sweat bands is preferably eliminated.
In this connection, the use of absorbent sweat bands is undesirable
in that such materials can and do become uncomfortably saturated or
stained from perspiration.
The cellular honeycomb is preferably constructed with the axes of
its open end cells extending perpendicularly therethrough. The cell
axes are thus substantially perpendicular to the surface of the
headwear. The radius of curvature of the contoured honeycomb
section is sufficiently short so as to establish a progressive
divergence of angularity between adjacent cells. The transmittal of
sunrays therethrough will be limited by the angle of incidence of
said rays on a particular cell and the transmittal angle of the
cell, all cells for a particular honeycomb having approximately the
same transmittal angle. It is preferred that the transmittal angle
for the honeycomb used in the headwear of this invention be not
greater than 45.degree. and preferably between 45.degree. and
30.degree.. Such range, it has been found, provides for an optimum
interrelationship between size, flexibility and overall weight of
the honeycomb material used in the forming of the headwear. As a
further requirement, the cellular honeycomb employed herein should
have a cross-sectional open cell area of at least about 90 percent
of the total area of the shaped crown.
As used herein, the term angle of incidence defines the angle made
by the sun's rays with a line perpendicular to the surface on which
the rays fall. Thus, the angle of incidence at a particular area on
the headwear corresponds to the angle between the sun's ray and the
axis of the cell at that area. The angle of transmittal, a function
solely of the honeycomb cell configuration, defines the maximum
incident angle of the sun's rays which can pass through a given
cell.
According to a second aspect of the present invention, a convenient
method for fabricating headwear of the type described hereinbefore
is provided. Specifically, the method comprises spirally winding
together an elongate flat strip and an elongate corrugated strip on
a headwear-shaped form. The flat and corrugated strips are thus
disposed in alternating arrangement defining open cells
therebetween. A cellular honeycomb is thus formed contoured to the
shape of the form. The form may correspond in shape to the crown of
the headwear, thus conveniently forming a crown section to which a
brim or visor may subsequently be attached. Alternatively, the form
may include a lower, outwardly extending, annular portion so as to
form a honeycomb brim integral with the crown.
According to the preferred embodiment of the method of the present
invention, the flat and corrugated strips are dispensed from fixed
supply rolls and the winding is accomplished by rotating the form.
The strips are preferably maintained substantially perpendicular to
the form during winding, so that the headwear thus produced will
advantageously possess the cell orientation described with respect
to the first aspect of the present invention.
The method of the present invention is advantageous in that the
honeycomb material is simultaneously fabricated and contoured, to
form the desired honeycomb headwear with a minimum of difficulty.
In contrast, the bending of a flat honeycomb sheet into the desired
contour might pose serious manufacturing difficulties.
Other features, modifications and advantages of this invention will
become apparent by reference to the accompanying drawings in which
similar characteristics of reference may represent corresponding
parts in each of the several views. In the drawings:
FIG. 1 is a cut-away perspective representational view of a cap
type headwear embodying the features of this invention;
FIG. 2 is an exploded partial side view of the shaped crown of FIG.
1 illustrating the relationship between the relative position of
the sun to the amount of light transmitted through the cells of the
honeycomb;
FIG. 3 is an enlarged perspective view of several cells of the
honeycomb as illustrated in FIG. 1;
FIG. 4 is a sectional view taken along line 4--4 of FIG. 3;
FIG. 5 is a perspective side elevation of a modified type of
headwear embodying the features of this invention;
FIG. 6 is a side elevation of a rotatable form having a cellular
honeycomb headwear partially formed thereon in accordance with the
method of the present invention;
FIG. 7 is an enlarged plan view of the central portion of the
headwear depicted in FIG. 6; and
FIG. 8 is a perspective view, still further enlarged, of a
plurality of cells of the honeycomb headwear depicted in FIG.
6.
Referring more specifically to the drawings, and particularly to
FIGS. 1 and 2, a cap construction is shown comprising a shaped
crown 10 having a visor 12 affixed thereto. If desired, the visor
may be integrally formed with the crown. The crown 10 is formed of
an arcuately contoured section of open end honeycomb material 14
having a plurality of open ended cells 16. The honeycomb material
may be folded or vacuum formed sheet plastic material such as
polyethylene, polyvinylchloride, acrylic and the like. The crown
may also be made from arcuately formed plastic impregnated paper,
fabric materials, aluminum or other light weight metal honeycomb
type materials. The material selected may be tinted, colored or
otherwise treated depending on decorative or other aesthetic
objects to be fulfilled. With the sun directly overhead, light will
be transmitted through cells 16 over a limited portion of the crown
10. In general, the portion of the crown through which light will
be transmitted will be of a function of the particular transmittal
angle for a given honeycomb construction and the incident angle of
the sun's rays. Light is transmitted only through those cells
wherein the angle of transmittal is greater than the angle of
incidence of the sun light. While some light will be transmitted
through the cells of the honeycomb, such constitutes a relatively
small percentage of the incident light falling upon the
headpiece.
Whether or not the user is moving or remaining static, the angle of
incidence of sunlight to the cells of the headpiece will constantly
be changing. If the wearer of the headgear remains motionless for a
prolonged period of time, still no one area will be subjected to an
extended exposure to sunlight as the relative movement of the sun
itself results in a changing angle of incidence.
The angle of transmittal is a function of the physical size of the
honeycomb as shown in FIG. 4. The depth d of the honeycomb is
measured along the cell axis, and the width w is measured across
the widest spacing in the cell. By increasing the depth of the
honeycomb cell, the angle of transmittal .theta. for a particular
cell is reduced. The depth to which the cells of a given honeycomb
should be constructed will primarily be a function of convenience
and aesthetics. The greater the depth, the more effective the light
blocking properties of the honeycomb. The depth of the honeycomb
cell may conveniently vary from as little as one-quarter of an inch
to as much as 1 inch or more. However, at depths less than
one-quarter of an inch, the width of the cells required to
effectively reduce light transmittal becomes so small as to result
in a loss of overall open cell area. At depths greater than 1 inch,
the headwear tends to become cumbersome, although still effective
to shade the wearer and provide a maximum of ventilation.
It is contemplated, that the angle of transmittal for a particular
honeycomb structure used in this invention will not exceed
45.degree.. For such an angle of transmittal, the ratio of depth to
width of a cell will be 1.00. The depth to width ratio for the
honeycomb cell for transmittal angles other than 45.degree. may be
calculated from the following formula:
where .theta. is the angle of transmittal.
Besides constructing the honeycomb cells so as to decrease the
angle of transmittal, the shade protection offered by the crown
itself may be increased by forming the crown in such a manner as to
increase the rate of progressive divergence between adjacent cells.
By increasing the radius of curvature of the arcuately contoured
section, an increased divergence of angularity can be affected.
In FIG. 5, a modified type of headwear is illustrated having a
crown 18 and a circular brim 20. Circular band 22 is affixed about
crown 18 and serves to visually delineate the boundary between the
crown and the brim. The brim may form part of the continuous piece
of honeycomb material used for the construction of the crown. It is
also contemplated that brims commonly used with existing headwear
be employed. Such brims or visors could be attached to the
honeycomb crown by any suitable means.
The term "cellular material" and/or "honeycomb" as may be used in
this Specification and in the claims is intended to include
substantially any form of cellular material having geometrically
shaped cells in cross-section and which can function to provide
both the required ventilation as well as sun-ray cut-off angles as
required.
The invention is not limited to the specific types of materials
from which the hat may be made or the manner in which such material
may be manufactured, fabricated or formed. It is visualized that
the honeycomb crown and/or other portions of the headpiece may be
made by either conventional honeycomb manufacturing techniques in
known configurations such as generally disclosed in representative
U.S. Pat. Nos. 2,610,934, 3,416,983, 3,342,666, and 3,205,109 or
such components may be formed in different configurations and
according to the manufacturers choice by techniques such as vacuum
forming extrusion, or molding or the like.
Referring now to FIGS. 6 through 8, a particularly convenient
method for manufacturing headwear of the general type described
hereinbefore will now be described in detail. Referring
specifically to FIG. 6, there is provided a headwear shaped form 30
rotatably mounted on a shaft 32. Form 30 may include a
crown-forming portion 30a, and a lower, outwardly extending annular
brim-forming portion 30b. As will be more readily apparent
hereinafter, brim-forming portion 30b functions to produce a
cellular honeycomb headwear having an integrally formed annular
brim. Alternatively, brim forming portion 30b may be deleted, so
that only a crown portion will be formed on the form 30. A brim or
visor may subsequently be attached to the crown, if desired, to
form the completed headwear.
In accordance with the method .[.fo.]. .Iadd.of .Iaddend.the
present invention, there is provided an elongate corrugated strip
34 and an elongate flat strip 36. Strips 34 and 36 are spirally
wound together on form 30 to form a contoured section of open cell
honeycomb in the shape of the desired headwear. Thus, the width of
strips 34 and 36 corresponds to the desired cell depth. The
cross-sectional shape and dimensions of the cells are determined by
the shape and dimensions of the corrugations of strip 34.
In greater detail, strips 34 and 36 may conveniently be provided on
supply rolls (not shown), and the ends thereof disposed at the
center of the top of the crown, shown generally at 40. Shaft 32 is
rotated, causing strips 34 and 36 to be drawn off the supply rolls
and spirally wound together on form 30. The spiral configuration
thus formed is best depicted in FIG. 7. It is apparent therefrom
that the spiral configuration thus formed spirals outwardly from
the top center 40 of the crown, with the corrugations in strip 34
cooperating with strip 36 to define a plurality of open cells 38
therebetween.
To facilitate the starting of the winding, a small cylindrical
mandrel (not shown) may be provided at the top center 40 of the
crown. The mandrel may comprise an upwardly extending portion of
form 30 which will thus be removed from the headwear upon
subsequent removal pf the headwear from form 30. Alternatively, the
mandrel may comprise a separate structure which may remain in the
headwear or may subsequently be removed.
A suitable adhesive is applied to either or both of the strips 34
and 36 prior to or during winding. Preferably, the adhesive is
applied only to those surfaces of the corrugations of strip 34
which will directly abut strip 36 upon winding, to minimize the
waste of adhesive on surfaces where it is unnecessary.
Referring specifically to FIG. 8, it is apparent that the spiral
winding procedure thus described may be regarded as forming an
alternation of flat strips 36 and corrugated strips 34, forming
rows of honeycomb cells 38. The cross-sectional shape of each of
the cells 38 is determined by the configuration of the corrugations
of strip 34, as referred to briefly hereinbefore. As best shown in
FIG. 8, corrugated strip 34 may typically comprise a series of
folds, at equally spaced locations, of somewhat more than
90.degree., the folds alternating in direction. The cells 38,
formed therefrom thus possess a generally trapezoidal
cross-sectional shape. Cells of square cross section may be
obtained by the use of a corrugated strip having equally spaced
90.degree. bends or folds. It is thus apparent that a particular
desired cell shape may be achieved by the judicious selection of
the corrugated strip.
The thus described spiral winding is continued until the entire
crown section, and brim if desired, of the headwear is formed. By
maintaining the strips 34 and 36 substantially perpendicular to the
surface of form 30 during winding, the honeycomb will be formed
with the cell axes perpendicular to the surface of the headwear, to
produce the headwear described hereinbefore, having the desired
shade-providing properties. Upon completion of the procedures thus
described, the honeycomb headwear thus formed is removed from form
30 to complete the fabrication.
Having thus described the foregoing invention in some detail by way
of illustration for the purposes of clarity and understanding, it
will be apparent to one skilled in the art that certain changes and
modifications may be practiced within the spirit of this invention
as limited only by the scope of the appended claims.
* * * * *