Abstract:
The present invention relates to a flexible plated cooling pack for headwear and a method for making the same that is capable of providing a sufficient cooling effect with a small amount of coolant, not causing worry about leakage of the coolant, and providing a cushion effect without a volume variance regardless of many uses, as well as the cooling effect. 
     The flexible plated cooling pack has an inner and outer synthetic resin film sheet bonded each other and a coolant filled therein, wherein the outer synthetic resin film sheet has a shape respectively corresponding to a piece of the crown portion and a sweatband and the coolant is always maintained in at least a gel state. The flexible plated cooling pack may be disposed in an inner portion of the crown portion and the sweatband of the headwear or may be inserted in a pocket formed at an inner portion of the crown portion and the sweatband of the headwear.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates to a flexible plated cooling pack for headwear, and a method for making the same. More particularly, the present invention relates to a flexible plated cooling pack for headwear and a method for making the same that is capable of providing a sufficient cooling effect with a small amount of coolant, without worry regarding leakage of the coolant, and that provides a cushion effect without a volume variance as well as the cooling effect. 
         [0003]    2. Description of the Related Art 
         [0004]    Generally, headwear includes a crown portion that is placed on a wearer&#39;s head and a visor portion protruding entirely or partially outward from the crown portion. 
         [0005]    Such headwear may prevent the face from being burned and the head and the like from being heated by direct rays of the sun or ultraviolet rays during hot weather such as the summer season, and may prevent the eyes from being exposed by the direct rays of the sun, thus it may be widely used generally or for sports. 
         [0006]    In addition, such headwear may prevent the head from being affected by cool weather because it is made of an insulating fabric, so that it may prevent a loss of heat. 
         [0007]    However, if the headwear is worn for a long time when the sunlight is strong and the temperature is high, the headwear may interrupt heat or sweat dissipation, and thus the sweat may build up or the head may be heated to a high temperature. 
         [0008]    For the purpose of solving such a problem, an ice pack filled with a coolant or refrigerant such as air or water is disposed thereto. 
         [0009]    However, such a coolant or refrigerant has a problem in that it may have the cooling effect for a relatively short time. Also, the coolant may easily leak though the ice pack and accordingly the leaked coolant may contaminate the headwear or the surroundings thereof. In addition, the coolant or refrigerant may be a solid because of a phase change and accordingly it may press the head painfully. 
         [0010]    In addition, the ice pack must have a relative large capacity so as to provide a sufficient cooling effect and must be previously refrigerated. Thus, it is difficult to always carry or keep the same. 
         [0011]    The above information disclosed in this Background section is only for enhancement of understanding of the background of the invention and therefore it may contain information that does not form the prior art that is already known in this country to a person of ordinary skill in the art. 
       SUMMARY OF THE INVENTION 
       [0012]    The present invention has been made in an effort to provide a flexible plated cooling pack for headwear and a method for making the same having advantages of providing a sufficient cooling effect with a small amount of coolant for a long time, being easily carried and kept, not causing worry about leakage of the coolant, and providing a cushion effect without a volume variance regardless of many uses so that the shape or design of the headwear may be maintained. 
         [0013]    An exemplary embodiment of the present invention provides a flexible plated cooling pack for headwear having a crown portion that is placed on the head, a visor portion protruding outward from at least a part of the crown portion to shield sunlight, and a sweatband disposed according to a head circumferential direction at a lower portion of the crown portion, wherein the flexible plated cooling pack having a shape corresponding to a piece, the piece composing the crown portion so that it is disposed at an inner portion thereof and having a coolant filled therein such that the coolant is always maintained in at least a gel state. 
         [0014]    According to an exemplary embodiment of the present invention, the flexible plated cooling pack may be fixed between a lower portion of the crown portion and the sweatband according to a head circumferential direction at a lower portion of the crown portion so that it may be easy to carry, keep, and replace the same. 
         [0015]    In addition, according to an exemplary embodiment of the present invention, the flexible plated cooling pack has an outer panel and a coolant, which are not cooled to sub-zero temperatures so that the user may always feel a cushion effect and the flexible plated cooling pack may closely contact the shape of the crown portion, and it may not change the same. 
         [0016]    In addition, according to an exemplary embodiment of the present invention, the flexible plated cooling pack has a plurality of lattices formed by high-frequency heating on the outer panel that has good elasticity and thermal transmission so that it may have sol filler uniformly that does not becomes thicker, and when it is pressed, the sol filling material may not easily leak such that it does not contaminate the head and surroundings thereof. 
         [0017]    According to an exemplary embodiment of the present invention, the flexible plated cooling pack has a wide flange on the periphery portion thereof, which is formed by the high-frequency heating, so that it may prevent the filling material from leaking and allow the flexible plated cooling pack to be easily connected to each other. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0018]      FIG. 1  is a perspective view of a flexible plated cooling pack in a state in which at least a portion thereof is inserted between a crown portion and a sweat band according to a first exemplary embodiment of the present invention. 
           [0019]      FIG. 2A  and  FIG. 2B  are respectively a perspective view and a cross-sectional view of a flexible plated cooling pack disposed along a circumferential portion of a crown portion according to an exemplary embodiment of the present invention. 
           [0020]      FIG. 3A  and  FIG. 3B  are respectively a perspective view and a cross-sectional view of a flexible plated cooling pack disposed along a height direction of a crown portion according to an exemplary embodiment of the present invention. 
           [0021]      FIG. 4  is a perspective view showing how a plurality of flexible plated cooling packs are connected to each other according to an exemplary embodiment of the present invention. 
           [0022]      FIG. 5  is a flowchart showing how to manufacture a flexible plated cooling pack according to an exemplary embodiment of the present invention. 
           [0023]      FIG. 6  shows a thermal image of a thermal mannequin according to an exemplary embodiment of the present invention. 
           [0024]      FIG. 7  is a perspective view of a flexible plated cooling pack in a state in which it is inserted into a pocket formed in each inner portion of a crown portion and a sweat band according to a second exemplary embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
       [0025]    A preferred exemplary embodiment of the present invention will be described with reference to attached drawings. 
         [0026]    In the following detailed description, only certain exemplary embodiments of the present invention have been shown and described, simply by way of illustration. 
         [0027]    As those skilled in the art would realize, the described embodiments may be modified in various different ways, all without departing from the spirit or scope of the present invention. 
         [0028]    Accordingly, the drawings and description are to be regarded as illustrative in nature and not restrictive. Like reference numerals designate like elements throughout the specification. 
         [0029]    According to an exemplary embodiment of the present invention, it is exemplified that the headwear is a golf cap, but it may be any item that may be worn on the head, such as a visor, a baseball cap, a sun cap, or another kind of hat. 
         [0030]    A flexible plated cooling pack and headwear having the same according to the first exemplary embodiment of the present invention will be described with reference to  FIG. 1  through  FIG. 3B  in detail. 
         [0031]      FIG. 1  is a perspective view of a flexible plated cooling pack in a state in which at least a portion thereof is inserted between a crown portion and a sweat band according to an exemplary embodiment of the present invention. 
         [0032]      FIG. 2A  and  FIG. 2B  are respectively a perspective view and a cross-sectional view of a flexible plated cooling pack disposed along a circumferential portion of a crown portion according to an exemplary embodiment of the present invention.  FIG. 3A  and  FIG. 3B  are respectively a perspective view and a cross-sectional view of a flexible plated cooling pack disposed along a height direction of a crown portion according to an exemplary embodiment of the present invention. 
         [0033]    As shown in  FIG. 1  to  FIG. 3B , according to an exemplary embodiment of the present invention, headwear  100  may include a crown portion  130  that is placed on the head, a visor portion  150  protruding to shield sunlight at a part or the entirety of the lower portion of the crown portion  130 , and a sweatband  170  having a fixed end portion  171  connected at the lower portion of the crown portion  130  and a free end portion  173  opposite thereto. The sweatband  170  may have elasticity. 
         [0034]    When the sweatband  170  has elasticity, it may stretch along the circumferential portion of the crown portion  130  so that it may provide good wearing comfort when wearing it regardless of the size of the head. It may have a width of 1.5 to 7 cm. 
         [0035]    Preferably, the sweatband  170  may be made from a monofilament fiber that makes it easier for the sweatband to maintain its original shape and guarantees free and comfortable movement due to its significant capacity to stretch and ability to spring back to its shape. The monofilament fiber may provide a softer, more natural feel and a more cotton-like characteristic when it is made from one of nylon, PET, polyethylene (PE), PP, or the like. 
         [0036]    According to an exemplary embodiment of the present invention, the headwear  100  may include at least a part of a flexible plated cooling pack  110  between the crown portion  130  and the free end portion  173  of the sweatband  170 . 
         [0037]    When the flexible plated cooling pack  110  has a shape corresponding to the plurality of pieces  131 ,  132 , and  133  of the crown portion  130  and the sweatband  150  disposed along the head circumferential direction of the crown portion  130 , a plurality of flexible plated cooling packs  110  may be easily connected to form uniform headwear and to provide a uniform cooling effect for the entirety of the head, and also each of the flexible plated cooling packs  110  may provide an efficient cooling effect. 
         [0038]    It is preferable for an outer synthetic resin film sheet  111  of the flexible plated cooling pack  110  to be made of a transparent and durable material such as thermoplastic polyurethane (TPU), so that it may be environmentally friendly, have good durability and elasticity, and may also have a freezing point of below −40° C. to provide a softer feel at sub-zero temperatures. In addition, it may have durability with respect to oil or fatty acids so that it may protect against leakage of oil or fatty acids stored therein. 
         [0039]    However, the present invention is not limited thereto. Any product that is environmentally friendly, transparent, and does not freeze at sub-zero temperatures may be used as the outer synthetic resin film sheet. It may be, for example, one of thermoplastic polyurethane, polyethylene, and polyvinyl acetate films as shown in Table 1. 
         [0040]    Table 1 shows what does not freeze at sub-zero temperatures and may be used as the outer synthetic resin film sheet. 
         [0000]    
       
         
               
               
               
             
           
               
                   
                 TABLE 1 
               
               
                   
                   
               
             
             
               
                   
                 TPU 
                 Not freezing 
               
               
                   
                 High-density polyethylene (HDPE) 
                 Freezing 
               
               
                   
                 Ethylene-vinyl-acetate (EVA) 
                 Freezing 
               
               
                   
                 Ethylene-propylene-dyne copolymer 
                 Freezing 
               
               
                   
                 (EPDM) 
               
               
                   
                 Polyethylene film 
                 Not freezing 
               
               
                   
                 Polyvinyl chloride 
                 Not freezing 
               
               
                   
                   
               
             
          
         
       
     
         [0041]      FIG. 2A  and  FIG. 2B  illustrate the flexible plated cooling pack  110  having a tape shape corresponding to the sweatband  150 . 
         [0042]    As shown  FIG. 2A  and  FIG. 2B , it may have a plurality of lattices  111   a  and a plurality of filling portions  111   b  for storing the coolant  120 . The plurality of lattices  111   a  are formed by means of thermally bonding the outer synthetic resin film sheet  111  and an inner synthetic resin film sheet  112  thereof and the plurality of filling portions  111   b  are surrounded by the plurality of lattices  111   a  disposed thereon. 
         [0043]    The flexible plated cooling pack  110  has a gap  111   c  for allowing the coolant  120  to flow and a flange portion  113  formed along the periphery portion thereof. The flange portion  113  is formed by means of thermally bonding the outer synthetic resin film sheet  111  and an inner synthetic resin film sheet  112  thereof. 
         [0044]    The flange portion  113  may have one formed to be broader than the other so that it may allow the flexible plated cooling pack  110  to be more easily inserted between the crown portion  130  and the sweatband  170 . 
         [0045]    The tape-like flexible plated cooling pack  110  has a width of less than that of the sweatband  170  so that it may closely contact the crown portion  130  while being covered by the sweatband  170 , and provides a cushioning effect at the forehead. 
         [0046]    Meanwhile, the coolant  120  may be a phase change material (PCM) slurry. 
         [0047]    The phase change material is defined as a latent heat storage material having a low melting point and a low vacuum change at phase change. The thermo-physical properties of the phase change material slurry, i.e., density, specific heat, thermal conductivity, and viscosity, were discussed for the temperature region of solid and liquid phases of the dispersion material (paraffin). 
         [0048]    In order to satisfy such features, a paraffin series material among 200 types of phase change materials includes a slurry phase so that it may maintain a gel state still after phase change to always provide a cushioning effect. 
         [0049]    Particularly, a common example thereof is RUBITHERM RT. 
         [0050]    The RUBITHERM RT has merits such as an excellent heat storage capacity, a recycling possibility, a long life cycle, constant endothermic and exothermic reactions, a stable phase change cycle, environmental friendliness, and non-toxicity. In addition, during a phase change cycle, it has stable performance and good chemical stability and has a melting point at a temperature of −4° C. to 100° C. such that it is adaptable to a user&#39;s surrounding environment as shown in Table. 2 
         [0051]    Table. 2 shows a performance of RUBITHERM RT 
         [0000]    
       
         
               
               
               
             
           
               
                 TABLE 2 
               
               
                   
               
             
             
               
                 Melting Point (approx) 
                 ° C. 
                 28 
               
               
                 Congealing Point (PCM) 
                 ° C. 
                 26 
               
               
                 Heat storage capacity 
                 kJ/(kg) 
                 179 
               
               
                 Temperature range 19° C. 
               
               
                 to 35° C. 
               
               
                 Density solid at 15° C. 
                 Kg/1 
                 0.87 
               
               
                 Density liquid at 70° C. 
                 Kg/1 
                 0.75 
               
               
                 Volume expansion 
                 % 
                 10 
               
               
                 Volume expansion r 
                 1/K 
                 0.001 
               
               
                 without phase change 
               
               
                 Specific heat capacity 
                 kJ(kg · K) 
                 1.8/2.4 
               
               
                 Heat conductivity 
                 W/(m · K) 
                 0.2 
               
               
                 Kin, Viscosity at 40° C. 
                 mm 2 /s 
                 4.5 
               
               
                 Flash Point(PCM) 
                 ° C. 
                 164 
               
               
                 Corrosion 
                   
                 Chemically inert with 
               
               
                   
                   
                 respect to most materials 
               
               
                 Water hazard 
                   
                 Water hazard class 
               
               
                   
                   
                 (WGK) 1 
               
               
                   
               
             
          
         
       
     
         [0052]    In addition,  FIG. 3A  and  FIG. 3B  illustrate the flexible plated cooling pack  110 ′ having a shape corresponding to the plurality of pieces  131 ,  132 , and  133  of the crown portion  130  (see  FIG. 1 ) 
         [0053]    As shown  FIG. 3A  and  FIG. 3B , it may have a plurality of lattices  111 ′ a  and a plurality of filling portions  111   b ′ for storing the coolant  120 ′. The plurality of lattices  111   a ′ are formed by means of thermally bonding the outer synthetic resin film sheet  111 ′ and an inner synthetic resin film sheet  112 ′ thereof and the plurality of filling portions  111   b ′ are surrounded by the plurality of lattices  111   a ′ disposed thereon. 
         [0054]    The flexible plated cooling pack  110 ′ has a gap  111   c ′ for allowing the coolant  120 ′ to flow and a flange portion  113 ′ formed along the periphery portion thereof. The flange portion  113 ′ is formed by means of thermally bonding the outer synthetic resin film sheet  111 ′ and an inner synthetic resin film sheet  112 ′ thereof. 
         [0055]    The flange portion  113 ′ may have a lower flange portion  113   a ′ formed to be broader than other portions so that it may allow the flexible plated cooling pack  110 ′ to be more easily inserted between the crown portion  130  and the sweatband  170 . 
         [0056]    Each flexible plated cooling pack  110 ′ may be disposed to the inside of the plurality of pieces  131 ,  132 , and  133  of the crown portion  130 , and may be in close contact with the crown portion  130  by means of a strong static electric force because the second flexible plated cooling pack  110 ′ is made of the synthetic resin film sheet  111  and the pieces  131 ,  132 , and  133  are made of fabric. 
         [0057]      FIG. 4  is a perspective view showing how a plurality of flexible plated cooling packs are connected to each other according to an exemplary embodiment of the present invention. 
         [0058]    As shown in  FIG. 4 , the flange portions  113  of the flexible plated cooling pack  110  are overlapped with the flange portions  113 ′ of the flexible plated cooling pack  110 ′ so that a uniform shape corresponding to the crown portion  130  may be provided and thus a uniform cooling effect may be provided for the entire portion of the head. 
         [0059]    Herein, a method for manufacturing a flexible plated cooling pack according to an exemplary embodiment of the present invention is described with reference to  FIG. 5 . 
         [0060]      FIG. 5  is a flowchart showing how to manufacture a flexible plated cooling pack according to an exemplary embodiment of the present invention. 
         [0061]    As shown in  FIG. 5 , in order to manufacture the flexible plated cooling pack  110  and  110 ′, the synthetic resin film sheet  111  and  111 ′ is cut from an elastic film into a shape corresponding to each of the pieces  131 ,  132 , and  133  for forming the crown portion  130  or the sweatband  150  (S 10 ). 
         [0062]    As described above, the synthetic resin film sheet  111  and  111 ′ may be made of a transparent and elastic film such as thermoplastic polyurethane film (TPU), so that it may be environmentally friendly, have good durability and elasticity, and may also have a freezing temperature of below −40° C. to provide a softer feel at sub-zero temperatures. In addition, it may have durability with respect to oil or fatty acids so that it may protect against leakage of the oil or fatty acids that is stored therein. 
         [0063]    Two cut synthetic resin (elastic) film sheets  111  and  111 ′ are then overlapped (S 20 ). 
         [0064]    When a hot bar or hot plate presses and heats the two overlapped synthetic resin film sheets  111  and  111 ′, Lattices  111   a  and  111   a ′ are formed with gaps  111   c  by means of thermally bonding (S 30 ). At this time, it is preferable to use a high-frequency bonding as the thermal bonding such that only the corresponding bonding portions of the synthetic resin film sheets  111  and  111 ′ are bonded. Accordingly, other parts of the elastic synthetic resin film sheets  111  may not be scorched and stick to each other. 
         [0065]    The high-frequency bonding uses a frequency of 500 to 1600 kHz to form a high-frequency electromagnetic field. Heat is generated due to an induced electricity loss to rapidly melt the material. The synthetic resin film sheets  111  and  111 ′ may be easily and appropriately processed by the high frequency bonding. 
         [0066]    The filling portions  111   b  and  111   b ′ surrounded by the lattices  111   a  and  111   a ′ are filled with the coolant that is injected though an injection portion  111   d  and  111   d′.    
         [0067]    The periphery portion of the synthetic resin film sheet  111  and  111 ′ having the filling portion  111   b  and  111   b ′ and the lattices  111   a  and  111   a ′ are sealed to form the flange portion  113  and  113 ′ by the high frequency bonding except for the injection portion  111   d  and  111   d ′ associated with the gap  111   c  and  111   c ′ (S 40 ). 
         [0068]    The slurry-phase coolant  120  is injected though the injection portion  111   d  and  111   d ′ to the filling portions  111   b  and  111   b ′ of the flexible plated cooling pack  110  and  110 ′ (S 50 ). 
         [0069]    When one filling portion  111   b  and  111   b ′ is filled with the coolant, another filling portion  111   b  and  111   b ′ is sequentially filled. Accordingly, the flexible plated cooling pack  110  may maintain a flat shape. 
         [0070]    When the filling is completed, the injection portion  111   d  and  111   d ′ is sealed with the high-frequency bonding (S 60 ). 
         [0071]    The cooling effect of the flexible plated cooling pack according to an exemplary embodiment of the present invention is described with reference to  FIG. 6 . 
         [0072]      FIG. 6  shows a thermal image of a thermal mannequin according to an exemplary embodiment of the present invention. 
         [0073]    As shown in  FIG. 6 , the headwear using a flexible plated cooling pack according to an exemplary embodiment of the present invention may maintain a constant temperature at the periphery portion of the head for a long usage time, while the periphery temperature is increased when the conventional headwear is used for a long time. 
         [0074]    Meanwhile,  FIG. 7  is a perspective view of a flexible plated cooling pack in a state in which at least a portion thereof is inserted in a pocket formed at an inner portion of a crown portion and a sweat band according to another exemplary embodiment of the present invention. 
         [0075]    As shown in  FIG. 7 , according to another exemplary embodiment of the present invention, headwear  100 ′ may include a crown portion  130 ′ that is placed on the head, a visor portion  150 ′ protruding to shield sunlight at a part or the entirety of the lower portion of the crown portion  130 ′, and a sweatband  170 ′. 
         [0076]    The crown portion  130 ′ and the sweatband  170 ′ may have a pocket  135  and  175 ′ at inner portion. 
         [0077]    The pocket  135  and  175 ′ may envelop the flexible plated cooling pack  110  and  110 ′. 
         [0078]    While this invention has been described in connection with what is presently considered to be practical exemplary embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.