PAPER-BASED HAT AND METHODS FOR MAKING SAME
Paper-based hats and methods for making same are disclosed. For example, a visor component and a crown component may be obtained from at least one paper-based material, such as a paper-based beverage carton. A crown-visor structure may be formed by affixing at least a portion of a non-exposed surface of the crown component to at least a portion of an upper portion of an exposed surface of the visor component. A band may be affixed to at least a portion of the crown-visor structure to support the paper-based visor on a head of a wearer of the paper-based hat. The visor component and/or the crown component may include images that were printed on the source paper-based material that are visible to an observer of the paper-based hat being worn by a wearer thereof.
Traditional source materials for manufacturing apparel include cotton, wool and various polyester-based products. These materials are popular because they are durable, readily formed into patterns for all types of clothing, and are capable of withstanding the stresses imparted by machines used to manufacture garments, such as industrial sewing machines, Serger machines, and presses (for example, for imprinting a pattern or logo). Attempts have been made to use non-traditional materials to produce various types of apparel. For instance, paper and foam materials have been used as a source material for hats. However, conventional hats made from paper and foam are generally either disposable and intended for limited use (for example, paper hats worn by certain restaurant employees) or do not provide the same quality products as traditional materials (for example, sweat absorption and normal use, such as putting on and/or removing the hat, lead to degradation of the hat materials such that the hat becomes useless for the wearer). Accordingly, there is currently not a hat made from non-traditional products, such as paper-based materials, that is attractive, comfortable, and sufficiently durable to withstand normal use by a wearer of the hat.
SUMMARYThe invention described in this document is not limited to the particular systems, methodologies or protocols described, as these may vary. The terminology used herein is for the purpose of describing particular embodiments only, and is not intended to limit the scope of the present disclosure.
It must be noted that as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural reference unless the context clearly dictates otherwise. Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art. As used herein, the term “comprising” means “including, but not limited to.”
In an embodiment, a paper-based hat may comprise a visor component and a crown component obtained from at least one paper-based material, at least a portion of a non-exposed surface of the crown component being affixed to at least a portion of an upper portion of an exposed surface of the visor component to form a crown-visor structure; and a band affixed to at least a portion of the crown-visor structure and configured to support the paper-based hat on a head of a wearer of the paper-based hat.
In an embodiment, a paper-based hat may comprise a crown component obtained from a first paper-based material and comprising at least one image element printed thereon and a crown edge lined at least partially lined with a crown edging material; a visor component comprising a second paper-based material and having at least one image element printed thereon, the visor component being configured to have a plurality of incisions in an upper portion thereof and a visor edge lined with a visor edging material, wherein at least a portion of a non-exposed surface of the crown component is affixed to at least a portion of an upper portion of an exposed surface of the visor component to form a crown-visor structure; a head interface structure affixed to a non-exposed surface of at least a portion of the crown-visor structure; and a band affixed to the crown-visor structure and configured to support the paper-based hat on a head of a wearer of the paper-based hat.
In an embodiment, a method of making a paper-based hat may comprise providing at least one paper-based material; obtaining a visor component from the at least one paper-based material; obtaining a crown component from the at least one paper-based material; forming a crown-visor structure by affixing at least a portion of a non-exposed surface of the crown component to at least a portion of an upper portion of an exposed surface of the visor component; and affixing a band to at least a portion of the crown-visor structure to support the paper-based visor on a head of a wearer of the paper-based hat.
The terminology used in the description is for the purpose of describing the particular versions or embodiments only, and is not intended to limit the scope.
In the following detailed description, reference is made to the accompanying figures, which form a part hereof. In the drawings, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative embodiments described in the detailed description, figures, and claims are not meant to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented herein. It will be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the figures, can be arranged, substituted, combined, separated, and designed in a wide variety of different configurations, all of which are explicitly contemplated herein.
The present disclosure is directed toward a paper-based hat constructed at least partially from paper-based materials. The paper-based hat may be configured as a “visor” or “visor style” hat including a visor component and an open crown component generated from paper-based materials. According to some embodiments, the visor component and the crown component may be generated from paper-based materials that include text and/or symbols for various products, companies, sports teams, universities, geographic locations, brands, and the like. In this manner, the paper-based hat may be configured to display the text and/or symbols of paper-based materials from which they were obtained. Accordingly, the paper-based hat may be configured for various purposes including, but not limited to, marketing, advertising, commemorating and/or celebrating an event, demonstrating brand loyalty, and/or providing camaraderie among fellow wearers and/or others having similar interests. In addition, the presence of the text and/or logos may make the paper-based hat appealing to one or more different demographic segments interested in the text and/or logos. For instance, the paper-based materials may include beverage containers, such as paper cartons for cans of beer, having text and symbols associated with the beverage producer. Paper-based hats constructed from such paper-based materials will therefore include the text and symbols from the paper cartons.
One or more components of the paper-based hat may be obtained from the paper-based material 205. For instance, the visor component 210 and/or the crown component 215 may be obtained from the paper-based material 205. In an embodiment, the visor component 210 and/or the crown component 215 may be printed, drawn, scored, perforated or otherwise demarcated on the paper-based material 205 and the visor component and/or the crown component removed from the paper-based material 205. For example, the visor component 210 and/or the crown component 215 may be cut from the paper-based material 205 using a pair of scissors, a saw, or other cutting tool. In an embodiment, one or more dies may be configured in the shape or substantially in the shape of the visor component 210 and/or the crown component 215. The dies may be pressed against the paper-based material 205 with sufficient force to cut out or substantially cut out the visor component 210 and/or the crown component 215, for example, in a manner that does not bend, crease, or otherwise deform the paper-based material. In an embodiment, the dies may be configured to perforate the paper-based material 205 to facilitate removal of the visor component 210 and/or the crown component 215 from the paper-based material. In an embodiment, the dies may be constructed from a rigid material, such as a metal material (for example, steel or steel alloys). In an embodiment, the dies may be pressed against the paper-based material 205 using a press or die cutting machine, such as a mechanical press, a hydraulic press, or the like.
The visor component 210 and/or the crown component 215 may be configured to have certain dimensions 260-275 based on various factors, including the size of the paper-based hat, the head-size of an intended wearer, the size of the paper-based material 205, or the like. In an embodiment, the visor component 210 may have a substantially central width 270 of about 11 inches and a substantially central height 275 of about two (2) and a quarter inches. In an embodiment, the visor component 210 may have a substantially half-circle shape formed similarly or substantially similarly to the visor or bill of a conventional baseball hat. In an embodiment, the crown component 210 may have a substantially central width 265 of about seven (7) inches, a substantially central height 260 of about four (4) and a half inches, and a length from a top peak to the center of the bottom area 280 of about six (6) and a quarter inches. In an embodiment, the crown component 210 may have a substantially elongated shape.
Embodiments are not limited to the particular size and shape of the visor component 210 and/or the crown component 215 described above and/or depicted in
Although
According to some embodiments, the visor component 210 and the crown component 215 may be cut from the same or different beverage container paper-based materials 205 such that the text 220 and/or symbols 225 line up on the finished paper-based hat to form a continuous or substantially continuous image. As shown in
After the visor component 305 and/or the crown component 310 has been removed from the paper-based material, a lining or edging 320 may be provided in whole or in part using various liner materials. The edging 320 may serve, among other things, to strengthen, provide rigidity, and/or to prevent fraying of the visor component 305 and/or the crown component 310. Illustrative edging 320 materials include, without limitation, deformable plastic materials, cotton, polyester materials, and/or any material capable of providing an edging for the visor component 305 and/or the crown component 310 according to embodiments described herein. The edging 320 may be affixed to the visor component 305 and/or the crown component 310 according to various methods, including, but not limited to, the use of staples, the use of glue, and/or sewing.
At least a portion of the non-exposed side of the crown component 410 may be affixed to at least a portion of the exposed side of the visor component 405 to form a crown-visor structure 445. For example, all, substantially all, or at least a portion of the upper portion 440 of the visor component 405 may be affixed to the crown component 410 using various methods. For instance, the visor component 405 may be affixed to the crown component 410 through the use of glue, the use of tape (for example, double-sided tape), the use of staples, sewing, and/or other methods known to those having ordinary skill in the art.
As shown in
As described above, the paper-based hat may include an at least partially elastic strap or band 435 capable of deforming to the shape or substantially to the shape of at least a portion of the head of a wearer of the paper-based hat. The ends of the band 435 may be affixed to the crown component 405, the visor component 410, the crown-visor structure 445, and/or the head interface component 430 according to various methods. Illustrative and non-restrictive methods include the use of glue, the use of tape (for example, double-sided tape), the use of staples, sewing, and/or other methods known to those having ordinary skill in the art.
The band 435 is configured to at least partially support the paper-based hat on the head of a wearer. For example, the crown-visor structure 445 and the band 435 may be configured to form a shape that may conform or substantially conform to the shape of the head of the wearer. The length of the band 435 may be configured such that the band may stretch when the wearer puts the paper-based hat on their head. The stretching of the band 435 may provide a force sufficient to hold the hat on the head of the wearer as known to those having ordinary skill in the art.
A paper-product based hat formed according to embodiments described herein is not limited by the paper-product based hats and/or components thereof illustrated in
In an alternate embodiment, a visor area on the at least one paper-based material may be determined 715 for the visor component and a crown area on the at least one paper-based material may be determined 720 for the crown component. The visor component and the crown component may be removed 725 from the at least one paper-based material. For instance, a die and press may be used to cut the visor component and the crown component from the paper-based material. In an optional step, at least a portion of the edges of the visor component and/or the crown component may be lined 730a with an edging material.
The visor component may be affixed 735 to the crown component to form a crown-visor structure. A head interface component may be affixed 740 to at least a portion of the crown-visor structure and a headband may be affixed 745 to at least a portion of the crown-visor structure to form the paper-based hat. In an optional step, the paper-based hat may be coated 750a with one or more coatings, such as a plastic and/or resin coating. The coating may serve to protect certain components of the hat and/or to provide an aesthetic quality to the hat. In an embodiment, the coatings may be transparent, substantially transparent, or semi-transparent such that the images on the components of the paper-based hat remain visible or at least partially visible after the coating or coatings have been applied. In another embodiment, the coatings provide a visible surface of the paper-based hat.
Embodiments are not limited to the steps and/or the order of the steps, including the optional steps, depicted in
It will be appreciated that various of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. It will also be appreciated that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which alternatives, variations and improvements are also intended to be encompassed by the following claims.
Claims
1. A paper-based hat comprising:
- a visor component and a crown component obtained from at least one paper-based material, at least a portion of a non-exposed surface of the crown component being affixed to at least a portion of an upper portion of an exposed surface of the visor component to form a crown-visor structure; and
- a band affixed to at least a portion of the crown-visor structure and configured to support the paper-based hat on a head of a wearer of the paper-based hat.
2. The paper-based hat of claim 1, wherein the paper-based material comprises at least one of the following: corrugated paper, cardboard, construction paper, paperboard boxboard, chipboard, carrier stock paper.
3. The paper-based hat of claim 1, wherein the paper-based material comprises a beverage container.
4. The paper-based hat of claim 1, wherein at least a portion of a visor edge of the visor component and at least a portion of a crown edge of the crown component are lined with an edging material.
5. The paper-based hat of claim 1, wherein at least a portion of an upper portion of the visor component comprises a plurality of incisions configured to prevent creasing of the visor component when being affixed to the crown component.
6. The paper-based hat of claim 1, wherein the visor component comprises a first portion of an image printed thereon and the crown component comprise a second portion of the image printed thereon.
7. The paper-based hat of claim 6, wherein the visor component and the crown component are obtained from the at least one paper-based material such that the first portion of the image and the second portion of the image line up to form a substantially continuous image on the paper-based hat.
8. A paper-based hat comprising:
- a crown component obtained from a first paper-based material and comprising at least one image element printed thereon and a crown edge lined at least partially with a crown edging material;
- a visor component comprising a second paper-based material and having at least one image element printed thereon, the visor component being configured to have a plurality of incisions in an upper portion thereof and a visor edge lined with a visor edging material, wherein at least a portion of a non-exposed surface of the crown component is affixed to at least a portion of an upper portion of an exposed surface of the visor component to form a crown-visor structure;
- a head interface structure affixed to a non-exposed surface of at least a portion of the crown-visor structure; and
- a band affixed to the crown-visor structure and configured to support the paper-based hat on a head of a wearer of the paper-based hat.
9. The paper-based hat of claim 8, wherein the paper-based material comprises at least one of the following: corrugated paper, cardboard, construction paper, paperboard boxboard, chipboard, carrier stock paper.
10. The paper-based hat of claim 8, wherein the paper-based material comprises a beverage container.
11. A method of making a paper-based hat comprising:
- providing at least one paper-based material;
- obtaining a visor component from the at least one paper-based material;
- obtaining a crown component from the at least one paper-based material;
- forming a crown-visor structure by affixing at least a portion of a non-exposed surface of the crown component to at least a portion of an upper portion of an exposed surface of the visor component; and
- affixing a band to at least a portion of the crown-visor structure to support the paper-based hat on a head of a wearer of the paper-based hat.
12. The method of claim 11, wherein the visor component is affixed to the crown component using at least one of the following: glue, staples, tape, and thread.
13. The method of claim 11, further comprising cutting a plurality of incisions in an upper portion of the visor component configured to prevent creasing of the visor component when affixing the visor component to the crown component.
14. The method of claim 11, wherein the paper-based material comprises at least one of the following: corrugated paper, cardboard, construction paper, paperboard boxboard, chipboard, carrier stock paper.
15. The method of claim 11, further comprising lining a visor edge of the visor component and at least a portion of a crown edge of the crown component with an edging material.
16. The method of claim 11, wherein the paper-based material comprises a beverage container having an image printed thereon.
17. The method of claim 16, wherein the visor component comprises a first portion of the image printed thereon and the crown component comprise a second portion of the image printed thereon.
18. The method of claim 17, wherein the first portion of the image and the second portion of the image line up to form a substantially continuous image on the paper-based hat.
Type: Application
Filed: Mar 13, 2013
Publication Date: Sep 18, 2014
Inventor: Peter A. Montana, II (Grand Island, NY)
Application Number: 13/801,804
International Classification: A42B 1/04 (20060101);