Abstract:
A hat pallet for use in a printer which prints an image onto a hat of the type having a cap and a brim attached thereto includes a bottom plate and a top plate mountable in a closed position over the bottom plate. The bottom plate includes a printing plate and a brim support fixedly mounted thereon. The top plate has an opening exposing at least a portion of the printing plate when the top plate is in the closed position. The brim support is positioned relative to the printing plate such that when the hat is mounted in the pallet with the top plate in the closed position, a portion of the cap on which the image is to be printed is supported on the printing plate and exposed through the opening of the top plate and the underside of the brim of the hat is supported by the brim support.

Description:
FIELD OF THE INVENTION 
       [0001]    This invention relates to direct printing of images on brimmed hats, and more particularly to a novel protector for a hat brim for use in high-temperature drying of the hat. 
       BACKGROUND OF THE INVENTION 
       [0002]    Direct printing of images or graphic designs onto apparel such as t-shirts and hats is typically performed by a high-speed digital image printer which prints ink onto an item of apparel. In order to prevent bleeding of ink, after printing, the printed area is typically cured by way of an ultra-violet (UV) curing lamp, an infra-red (IR) curing lamp, hot air, etc. For example, baseball caps printed with an image using a digital inkjet printer may be passed through a high-temperature (e.g., 350° F.) dryer to cure the ink. Furthermore, because industrial direct digital printers typically print according to a CMYK printing process in which the colors Cyan, Magenta, Yellow, and Black are each printed on separate layers, the printing and curing process requires several passes of the hat through the printer and dryer. 
         [0003]    In items of apparel that include plastic or other material that melts under the high drying/curing temperatures, the curing of the printed image may actually cause damage to elements of the item of apparel. For example, a baseball cap typically is formed with a plastic insert inside the brim of the hat as a stiffener and to maintain shape the brim. When the baseball cap is subjected to the curing process, the plastic inside the brim may melt or deform, which is clearly an undesired effect. Accordingly, a need exists for a hat brim protector and shaper which prevents damage to the brim of the hat and which simultaneously operates to fix the shape of the brim during the curing process. 
       SUMMARY 
       [0004]    Embodiments of the invention are directed at protecting and shaping the brim of a hat during the curing process in direct digital image printing on the hat. 
         [0005]    In accordance with one embodiment of the invention, a brim protector for a hat of the style including a cap with a brim attached thereto, includes a mitt having a cavity conforming to a desired brim shape and having an opening to the cavity conforming to a cross-section of the desired brim shape for inserting the brim of the hat therein, the mitt covering the entire brim when the brim is fully inserted into the mitt cavity, the mitt comprising a stiff heat-resistant material. 
         [0006]    In accordance with another embodiment of the invention, a method for protecting a brim of a hat of the style of a cap with a brim includes inserting the brim of the hat fully into a mitt, the mitt having a cavity conforming to a desired brim shape and having an opening to the cavity conforming to a cross-section of the desired brim shape for inserting the brim of the hat therein, the mitt covering the entire brim when the brim is fully inserted into the mitt cavity, the mitt comprising a stiff heat-resistant material, exposing the hat with brim inserted into the mitt to drying means, and removing the hat from the mitt to produce a dry hat with a brim shaped into the desired brim shape. 
         [0007]    In accordance with another embodiment of the invention, a method for making a brim protector for a hat comprising a cap having a brim attached thereto, includes forming a mitt configured with a cavity conforming to a desired brim shape and having an opening to the cavity conforming to a cross-section of the desired brim shape for inserting the brim of the hat therein, the mitt covering the entire brim when the brim is fully inserted into the mitt cavity, the mitt comprising a stiff heat-resistant material. 
         [0008]    In accordance with another embodiment of the invention, a dryer conveyance system includes a conveyor which passes through a dryer, and at least one brim protector attached to the conveyor, the brim protector configured to protect a brim of a hat, the hat comprising the brim attached to a cap, the brim protector comprising a mitt having a cavity conforming to a desired brim shape and having an opening to the cavity conforming to a cross-section of the desired brim shape for inserting the brim of the hat therein, the mitt covering the entire brim when the brim is fully inserted into the mitt cavity, the mitt comprising a stiff heat-resistant material 
         [0009]    It is an advantage of the invention that the brim of the hat is fully protected during drying or exposure to high temperatures and that during the drying process, the brim of the hat is shaped into a desired brim shape. 
         [0010]    These and other objects, features and advantages of the invention will be better understood with reference to the accompanying drawings, description and claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]      FIG. 1A  is a side view of a digital image printing system for printing digital images directly onto apparel; 
           [0012]      FIG. 1B  is a top view of the digital image printing system of  FIG. 1A ; 
           [0013]      FIG. 2  is a front view of a traditional baseball cap; 
           [0014]      FIG. 3A  is a perspective view of an exemplary embodiment of a hat brim protector; 
           [0015]      FIG. 3B  is a front view of the hat brim protector of  FIG. 3A  where a hat may be inserted into the opening of the protector; 
           [0016]      FIG. 3C  is a top-down view of the hat brim protector of  FIGS. 3A-3B ; 
           [0017]      FIG. 3D  is a side view of the hat brim protector of  FIGS. 3A-3C ; 
           [0018]      FIG. 4  is a flowchart illustrating an exemplary embodiment of a method for protecting a brim of a hat; 
           [0019]      FIG. 5  is a flowchart illustrating an exemplary embodiment of a method for making a brim protector for a hat; 
           [0020]      FIG. 6A  is a side view of another exemplary embodiment of a hat brim protector; 
           [0021]      FIG. 6B  is a top-down view of the hat brim protector of  FIG. 3A ; 
           [0022]      FIG. 6C  is a side view of the hat brim protector of  FIGS. 3A-3B  with a hat mounted on the protector; 
           [0023]      FIG. 6D  is a top-down view of the hat brim protector of  FIGS. 3A-3C  with a hat mounted on the protector; 
           [0024]      FIG. 7A  is side view of a dryer conveyance system; and 
           [0025]      FIG. 7B  is a top-down view of a dryer conveyance system. 
       
    
    
     DETAILED DESCRIPTION  
       [0026]    It will be understood that, while the discussion herein describes an embodiment of the invention in the field of printing images on baseball caps, it will be understood that the invention is not so limited and is relevant to any application for drying or curing a brim of a hat under high temperatures. 
         [0027]      FIGS. 1A and 1B  illustrate a digital image printing system  100  for printing digital images directly onto apparel such as t-shirts and hats. The printing system includes a printer  101  having a printing table  102  having a pallet  104  mounted thereon for holding an apparel piece  110 . The printer  100  also includes an array of inkjet print heads  106 . The printing table  102  is mounted on a conveyance system  112  which conveys the printing table  102  along a pre-determined path past the operative ends of the print heads  106 . The conveyance system  112  may be any automated or manual means for conveying the printing table  102  along the pre-determined path. For example, in one embodiment, the conveyance system  112  is an automated conveyor belt system under the control of a computer program. In another embodiment, the conveyance system  112  is a set of rollers over which the printing table slides when manually guided by a human operator. 
         [0028]    A controller  114  is coupled to the printer  101  for causing printing of a digital image  205  (see  FIG. 1B ) on the apparel piece  110  on the pallet  104  as the printing table  102  passes the print heads  106 . For a color image, the printing of the image is achieved by placing ink drops at different adjacent sites as discreet, physically non-mixed drops. The ink composition used must prevent the drops from “bleeding” on the applied media. In the illustrated embodiment, the image is printed by an array of color printing heads  114 . The image is printed using subtractive primary colors: Cyan, Yellow, Magenta, and Black (CYMK), for example, using transparent ink. When printing on dark colored apparel, a layer of white ink may first be printed prior to printing the CYMK process. The printing may require a single pass, or series of passes, to complete the printing of the image on the apparel piece  110 . 
         [0029]    After the printing process is complete, the printed item of apparel is placed on a conveyance mechanism, such as a conveyor belt  109 , which transports the item past the dryer  108  to cures the ink deposited by the inkjet printing heads  106 . The dryer  108  can be any drying mechanism, such as a hot air generator, an oven, etc. 
         [0030]      FIG. 2  depicts a standard baseball cap  200 . As shown, the baseball cap  200  includes a soft cap  202 , for example made of fabric, with a brim  204  in the form of a long, stiffened and curved peak. The cap  202  may be fitted. Alternatively, the back of the cap  202 , not shown, may include an adjustor strap made from plastic, Velcro, or elastic, so that it can be quickly adjusted to fit the size of the head of the wearer. The cap  202  is generally hemispherically shaped wherein the 3-dimensional curves are achieved by sewing a plurality of sections  203  together. Since the brim  204  is traditionally worn over the eyes, the printed image  206  is typically printed on the cap  202  above the brim  204 . The brim  204  is typically formed with a stiffener  205  covered with fabric to maintain the shape of the brim  204 . The stiffener  205  often comprises a plastic or other material that may be damaged or otherwise deform under drying temperatures (for example, 350° F.). 
         [0031]      FIGS. 3A-3D  together illustrate an exemplary embodiment of a novel hat brim protector  300  for a baseball cap  200 . As illustrated in  FIGS. 3A-3D , the hat brim protector  300  comprises a mitt  301  having top piece  302  and a bottom piece  303  enclosing a cavity  304  conforming to a desired brim shape and providing an opening  305  to the cavity  304  conforming to a cross-section A-A of the desired brim shape of the hat. At least the top piece  302 , and preferably also the bottom piece  303  of the mitt  301 , is made of a stiff heat-resistant material  306  such as Teflon® material, which may or may not be reinforced with a stiff material such as steel (e.g., steel reinforced Teflon® material) and may include an insulative material  307  layered between the inner cavity  304  and the stiff heat-resistant material  306 . The outer surface of the mitt may be coated in a heat deflection coating  308  such as Teflon® with a Kevlar® coating. In one embodiment, the edge  312  of the mitt  301  where the opening  305  is located is curved to follow the curve of the brim  204  where the brim  204  is attached to the cap of the hat  200 . 
         [0032]    A heat-resistant handle  310  is attached to an outer surface of the mitt  301 . While the embodiments shown have the handle  310  positioned on the top piece  302  of the mitt  301 , it will be appreciated that the handle  310  may be alternatively attached in different locations on the mitt  301 , such as along the edge opposite the opening  305 , or even on the bottom piece  303 . The handle  310  is made from a heat resistant material, and is preferably coated with a heat deflection coating. 
         [0033]      FIG. 4  is a flowchart illustrating a method  400  for protecting a brim of a hat configured with a brim connected to a cap. As illustrated, the method includes inserting the brim of the hat fully into the cavity of the mitt through the mitt opening (step  402 ). The mitt is one such as shown in  FIGS. 3A-3D , comprising a stiff heat-resistant material and wherein the cavity conforms to a desired brim shape. Preferably, while the brim is fully covered by the mitt, the cap itself remains unencumbered by the mitt, with little or no part of the mitt actually covering any portion of the cap. 
         [0034]    Returning to the method  400 , once the brim of the hat is fully inserted into the cavity of the mitt, the hat, together with the brim protector covering the brim, is exposed to drying means (step  404 ). For example, the hat may be placed on a conveyor belt which transports the hat  200  past a high-pressure, high-temperature hot-air dryer  108  or some other hot radiation means such as an oven. Because the mitt  301  itself is formed of heat-resistant material, exposure to high temperatures does not melt or otherwise damage the plastic (or other material) stiffening insert  205  inside the brim  204  of the hat  200 . Furthermore, because the mitt is formed of a stiff material, such as steel reinforced Teflon®, the brim is forced to conform to the shape of the mitt cavity  304 , which is the desired brim shape. After exposure to the drying means, the hat  200  is then removed from the mitt  301  (step  406 ), with the result being a dry hat having a brim shaped into the desired brim shape. 
         [0035]      FIG. 5  illustrates a method  500  for making the brim protector embodied herein. In this method  500 , a mitt  301  is formed of a stiff heat-resistant material (step  502 ), the mitt  301  configured with a cavity  304  conforming to a desired brim shape and having an opening  305  to the cavity conforming to a cross-section of the desired brim shape for inserting the brim  204  of the hat  200  therein. In one embodiment, the mitt is formed in a mold with Teflon® as the mitt material. In one embodiment, the Teflon® is a rigid material of approximately ⅜″ thickness. Preferably, the mitt  301  is configured to fully cover the entire brim when the brim is fully inserted into the mitt cavity yet leaves the cap  202  fully exposed. In one embodiment, the stiff heat-resistant material comprises steel reinforced Teflon®. Also, the mitt may be further formed with an insulative material layered between the inner cavity and the stiff heat-resistant material. The method  500  may also include the step of coating the outer surface of the mitt with a heat deflection coating, such as Teflon® with a Kevlar® coating (step  504 ). The method may further include the step of attaching a heat-resistant handle, preferably coated with a heat deflection coating, to an outer surface of the mitt (step  506 ). 
         [0036]      FIGS. 6A-6D  illustrates an enhancement to the brim protector of  FIGS. 3A-3D . The enhancement is a cap support  601  attached to the brim protector  300  which supports the cap  202  of the hat  200  while the brim  204  of the hat  200  is fully inserted into the mitt cavity  304 . As illustrated, in one embodiment, the cap support  601  is an oval hemisphere which mimics the top portion of a head. The illustrated embodiment of the cap support  601  is shown by way of illustration only and not limitation. Any cap support means which supports the cap so that the fabric of the cap is maximally exposed may be implemented in its place. 
         [0037]      FIGS. 7A and 7B  show a dryer conveyance system  700  having multiple brim protectors fixedly attached to a conveyance mechanism  702  (e.g. a conveyor belt) of the conveyance system  700 . The conveyance mechanism  702  transports the brim protectors in a continuous loop past a dryer mechanism  704 . Hats  200  may be inserted in a brim protector  300  as it passes by a loading station  708  and may be removed from the brim protector  300  when it reaches an unloading station  710 . The continuous loop allows maximum efficiency in loading and unloading multiple hats in an assembly line manner. Alternatively, or additionally, the brim protectors may include a cap support  601  such as shown in the embodiment of  FIGS. 6A-6D . 
         [0038]    Variations of the illustrated brim protector may be implemented without departing from the scope of the claimed invention. 
         [0039]    While an exemplary embodiment of the invention has been discussed, the described embodiment is to be considered as illustrative rather than restrictive. The scope of the invention is as indicated in the following claims and all equivalent methods and systems.