Patent ID: 6138279
Filing Date: 2000-10-31
Classification: A42B,A42C

Abstract:
The method of manufacturing a visor insert for a hat comprising the steps of:a) providing a visor insert of flexible, long lasting memory thermoplastic resin material having a thickness from about 0.045"" to about 0.075"", a tensil strength of between about 2750 psi to about 5000 psi, a flexural strength of between about 1680 psi and about 8500 psi, a flexural modulus elasticity of between about 45,000 psi to about 280,000 psi, and a melt temperature of about 470.degree. F. to about 510.degree. F.;b) flexing said visor insert to a desired shape;c) placing said flexed visor insert in a jig set to said desired shape;d) heating said visor insert in said jig to a temperature of about 350.degree. F. and about 375.degree. F. and maintaining said temperature for at least about 15 minutes minimum to reset the crystalline structure and long lasting memory of said thermoplastic resin material of said visor insert to the desired shape;e) gradually cooling said visor insert in said jig to a temperature of less than about 150.degree. F. over a period of about 40 minutes to about 60 minutes after said at least 15 minutes heating to avoid degradation and loss of said reset long lasting memory and removing from said jig; andf) whereby said visor insert upon removal from said jig will retain the desired shape even under distortion of said visor insert and under temperatures of about 180.degree. F. to about 200.degree. F. for a period of at least 5 hours without loss of said reset long lasting memory.