Patent Publication Number: US-2015082835-A1

Title: Composite waterproof breathable elastic hats and methodology and dies used to manufacture such hats

Description:
This invention relates to composite waterproof breathable elastic hats, and methodologies and dies for the manufacture of such hats. 
     In an outdoor exercise environment protection of the head is extremely important, and the importance of a hat as an accessory goes without saying. However in some severe or extreme outdoor conditions, a normal hat may manage to keep the wearer warm but fail in other special functional requirements for outdoor protection, such as wind-protection, rain protection, snow protection etc. To solve this technical problem current technology generally applies a pre-bonded waterproof and breathable fabric incorporated by cutting and stitching, as shown in  FIGS. 1 and 1A . Waterproof breathable outdoor hats made with this technology have seams where the fabric is stitched because of the technique used, and can only be made 100% waterproof by adpressing the waterproof adhesive (label  1 ) to the seam. Seamless joining is not possible. 
     To solve the technical problem of seamless joining, some current technology offers a knitted waterproof breathable hat as shown in  FIG. 2 . The technique uses a previously moulded waterproof breathable membrane hood ( 2 ) which is stitched directly between the knitted hat&#39;s inner layer ( 3 ) and outer layer ( 4 ), achieving a waterproof effect without a seam. However, hats made using this technique can see slippage occur between the membrane and the knitted inside and outside of the hat, as shown in  FIG. 2A , the membrane cannot be completely integrated with the inside or outside, giving rise to discomfort for the wearer and makes scratching noises. The wearer experiences extreme discomfort and wearing this hat for certain activities like hunting or military patrols could have very adverse consequences. Furthermore, because the membrane layer in this hat is slippery it is unable to be elastic and stretchable in all directions, so that the hat is less comfortable to wear than normal knitted hats. 
     The technology in the present invention solves the problems in existing technology which have been outlined above, whilst producing a protective hat that has waterproof and breathable properties, as well as preserving comfort experienced when wearing a normal knitted hat. 
     According to aspects of the present invention there is provided a composite waterproof breathable elastic hat comprising a knitted outer layer, a lining and a waterproof breathable membrane hood, in which the waterproof breathable membrane hood is attached to an attachment surface on the outside of the lining and/or to an attachment surface on the inside of the outer layer. 
     The lining may be knitted, made of a highly elastic spandex knit or made of woven cloth cut and stitched. 
     The outer layer may be made of a highly elastic spandex knit or of woven cloth cut and stitched. 
     The outer layer may be attached to the lining. 
     The outer layer may be stitched to the lining. 
     The outer layer may be stretchable from a relaxed condition to a stretched condition. 
     The lining may be stretchable from a relaxed condition to a stretched condition. 
     Then waterproof breathable membrane hood may have a greater surface area than either of the outer layer and lining when said outer layer and lining are in the relaxed condition. 
     The waterproof breathable membrane hood may be non-elastic or substantially non-elastic. 
     The waterproof breathable membrane hood may be attached to the lining and/or outer layer at a plurality of spaced locations. 
     The waterproof breathable membrane hood may be attached to the lining and/or outer layer at a plurality of substantially uniformly spaced locations. 
     The waterproof breathable membrane hood may be adhered to the lining and/or outer layer at a plurality of spaced locations over the attachment surface of one or both of the lining and outer layer. 
     The lining and/or outer layer may be adhered with one or more of TPU [thermoplastic polyurethane], PES [polyester] and PA [polyamide, nylon]. 
     The hat may be stretchable from a resting condition in which the outer layer and lining are in their relaxed condition and the waterproof breathable membrane hood has a wrinkle, puckered or generally corrugated conformation between the outer layer and the lining, and an extended condition in which the outer layer and lining are in their stretched condition and the waterproof breathable membrane hood is in a flat or less wrinkled, less puckered or less corrugated conformation. 
     The waterproof breathable membrane hood may have a bi-directional wrinkled or corrugated conformation, such that it is wrinkled, puckered or corrugated generally in both the longitudinal and circumferential directions, when the hat is in the resting condition, from which the waterproof breathable membrane hood can move with the outer layer and lining when the outer layer and lining are extended to their stretched conditions as the hat is taken from its resting condition, to give the hat two way stretch characteristics. 
     The waterproof breathable membrane hood may comprise bonded layers pressed together using a high temperature sealing machine or a high frequency plastic bonding machine or high frequency welding. 
     According to further aspects of the present invention there is provided a method of manufacturing a composite waterproof breathable elastic hat, the method comprising stretching a lining or outer layer over a die or mould, positioning a waterproof breathable membrane hood over the lining or outer layer and stretching an outer layer or lining over the waterproof breathable membrane hood, attaching the lining and/or the outer layer to the waterproof breathable membrane hood to form a hat structure which upon removal from the die or mould contracts until the lining and/or layer are in a relaxed condition and the waterproof breathable membrane hood is located therebetween in a wrinkled, puckered or corrugated conformation. 
     According to yet further aspects of the present invention there is provided a method of manufacturing a composite waterproof, breathable elastic hat, the method comprising stretching a lining or outer layer over a die or mould, positioning a waterproof breathable membrane hood over the lining or outer layer, attaching the lining or outer layer to the waterproof breathable membrane hood to form a bi-layer, which upon removal from the die or mould contracts until the lining or outer layer is in a relaxed condition and the waterproof breathable membrane hood is attached to the lining in a wrinkled, puckered or corrugated conformation. 
     The membrane hood may be positioned over the lining or outer layer in a relaxed, non-stretched condition. 
     Adhesive may be applied to the lining and/or outer layer and/or waterproof breathable membrane hood at discrete, spaced locations. 
     The adhesive may be applied prior to locating the waterproof breathable membrane hood and/or the lining and/or the outer layer over the die. 
     The adhesive may be spotted, dusted and/or taped on the respective one or more of lining, outer layer and/or waterproof breathable membrane hood. 
     The adhesive may be melted or softened on the die to adhere the waterproof breathable membrane hood and the lining and/or outer layer together. 
     The other of a lining or outer layer may be positioned over the bi-layer to form a hat structure. The hat structure may be stitched along or near its edge to form a hat. 
     According to further aspects of the present invention there is provided a hat structure for a composite waterproof breathable hat, the structure comprising an elastic outer layer or elastic lining and a non-elastic or substantially non-elastic breathable membrane hood attached to an attachment surface on the lining or outer layer. 
     The waterproof breathable membrane hood may be attached to the lining or outer layer as described above. 
     According to still further aspects of the present invention there is provided a die or mould for the manufacture of a composite waterproof breathable elastic hat and/or has structure defined in any of the preceding twenty-six paragraphs, in which the die comprises a forming surface on which the hat or hat structure is formed, the forming surface being arranged and dimensioned to receive and form the waterproof breathable membrane hood in its relaxed condition. 
     The die may comprise a flat-plate die with the same flat dimensions as the waterproof breathable membrane hood. 
     According to further aspects of the present invention there is provided a compound waterproof breathable elastic knitted hat, the hat has a knitted outer layer and lining along with a waterproof breathable membrane hood, characterized in that the waterproof breathable membrane hood referred to, is attached by use of a compound die to the outside of the hat lining (the attachment surface) and/or to the inside of the outer layer (the attachment surface), forming a multi-function sandwich layer. 
     Further, the hat&#39;s lining described is knitted, or cut and stitched from highly elastic spandex knit or woven cloth. 
     Further, the hat&#39;s outer layer described is knitted, and may be stitched to the inner layer to form one piece. 
     Further, the waterproof breathable membrane hood as described is first pressed together using a high temperature sealing machine or by a high frequency plastic bonding machine. 
     Further, the dimensions of the waterproof breathable membrane hood as described, when extended are larger than the flat dimensions of the outer layer and/or lining which are attached to it to form a multi-function sandwich layer. 
     Further, the adhesive used to attach the multi-function sandwich layer as described is TPU, PES or PA melt adhesive. 
     Further, the melt adhesion as described employs melt adhesion technology with an off-set point arrangement or dusting, with prior preparatory application to the attachment surface of the waterproof breathable membrane cap as described or to the attachment surface(s) of the outer layer or lining of the hat which makes up the multi-function sandwich layer. 
     Further, after the multi-function sandwich layer as described has been adhered and then removed from the compound die as described, the membrane of the waterproof breathable hood as described takes on a bi-directional corrugated structure (walnut wrinkling), with the result that the membrane layer as described acquires the characteristics of being able to be stretched in any direction along with the elastic material to which it has been attached. 
     This invention also introduces a die for the manufacture of the compound waterproof breathable elastic knitted hat as described, characterized in that the compound die used to make a multi-function sandwich layer as described is a flat-plate die with the same flat dimensions as the waterproof breathable membrane hood as described. 
     This invention also introduces a process for making the compound waterproof breathable elastic knitted hat as described, characterized in that: 
     Step  1 , the hat lining and/or external layer to be attached are placed on a compound die as described; 
     Step  2 , the waterproof breathable membrane hood described is slipped on top, and the hood is brought in contact with the hot melt adhesive points or dusting applied in preparation; 
     Step  3 , the hat lining to be attached and/or the outer layer is adhered by a hot press, forming a multi-function sandwich layer; 
     Step  4 , the multi-function sandwich layer as described and the parts of the hat which have not been adhered are stitched together along edges of the hat as described, forming a complete hat. 
    
    
     
       The present invention will now be described by way of example only, with reference to the accompanying drawings, in which: 
         FIG. 1  is a diagram of a waterproof hat cut and stitched using current technology; 
         FIG. 1A  is the seam of the cut and stitched waterproof hat as shown in  FIG. 1 ; 
         FIG. 2  is a diagram of a waterproof knitted hat using current technology in which a waterproof hood is inserted by stitching; 
         FIG. 2A  is a cross-section of the waterproof breathable hood between the lining and outer layer of the waterproof knitted hat, as shown in  FIG. 2 ; 
         FIG. 3  is a diagram of how the present invention uses heat sealing technology to make a multi-function sandwich layer; 
         FIG. 3A  is a cross-section of the waterproof breathable hood between the lining and outer layer of the waterproof knitted hat, as shown in  FIG. 3 ; 
         FIGS. 4A-4C  is a structure diagram of the off-set hot melt adhesive point sealing technology used in the present invention; 
         FIG. 4A  is the structure before sticking of the waterproof hood as shown along with the lining stretched and then slipped over a compound die; 
         FIG. 4B  is the structure after the adhesion of the waterproof hood as shown along with the hat lining stretched and then slipped over a compound die; 
         FIG. 4C  is a structure diagram of the waterproof hood and the hat lining after they have been adhered and removed from the die, producing corrugations. 
     
    
    
       1  Line of the seamed waterproof hat where waterproofing is adpressed 
       2  Waterproof hood using current technology 
       3  Hat lining using current technology 
       4  Hat outer layer using current technology 
       5  Hat outer layer using this invention 
       6  Hat lining using this invention 
       7  Waterproof hood using this invention with prior application of hot melt adhesive points 
       8  Compound die used with this invention 
     The present invention provides a composite waterproof breathable elastic hat comprising a knitted outer layer  5 , a lining  6  and a waterproof breathable membrane hood  7  in which the waterproof breathable membrane hood  7  is attached to an attachment surface on the outside of the lining  6  and/or to an attachment surface on the inside of the outer layer  5  such as to form a hat structure. 
     In more detail, the lining  6  is knitted, made of a highly elastic spandex knit or made of woven cloth cut and stitched. The outer layer  5  is typically made of a highly elastic spandex knit or of woven cloth cut and stitched. 
     In certain embodiments the outer layer  5  is attached to the lining  6  and is typically stitched to the lining  6 . 
     The outer layer  5  is stretchable from a relaxed condition to a stretched condition. Similarly the lining  6  is stretchable from a relaxed condition to a stretched condition. The waterproof breathable membrane hood  7  has a greater surface area than either of the outer layer  5  or the lining  6  when the outer layer  5  and lining  6  are in their relaxed condition and the waterproof breathable hood is non-elastic or substantially non-elastic (non-stretchable). 
     The waterproof breathable membrane hood  7  is attached to one or both of the lining  6  and outer layer  5  at a plurality of spaced locations, which spaced locations can be uniformly or generally uniformly spaced. 
     The waterproof breathable membrane hood  7  is adhered to the lining  6  and/or outer layer  5  at a plurality of spaced locations over the attachment surface of one or both of the lining  6  and outer layer  5 . 
     A thermosetting adhesive including one or more of a thermoplastic polyurethane, (TPU), polyester (PES) and/or polyamide (PA) can be used. 
     The hat structure can be secured by stitching typically along or near the edge thereof to form a hat. 
     The hat is stretchable from a resting condition in which the outer layer  5  and the lining  6  are in their relaxed condition and the waterproof breathable membrane hood has a wrinkled or generally corrugated or puckered conformation between the outer layer  5  and the lining  6 , and an extended condition in which the outer layer  5  and lining  6  are in their respective stretched condition and the waterproof breathable membrane hood  7  is in a flat or less wrinkled or less puckered or less corrugated conformation. 
     When the hat is in its resting condition the waterproof breathable membrane hood  7  has a bi-directional wrinkled, puckered or corrugated conformation so that when the hat is stretched from the resting condition, such as to be worn on the head of a user, the waterproof breathable membrane  7  can move or expand (even though it is not inherently stretchable) with the outer layer and lining, by the flattening of the wrinkles or corrugations, allowing the hat to stretch whilst retaining its waterproof characteristics. 
     Attaching one or both of the lining  6  and outer layer  5  to the waterproof breathable membrane hood helps to ensure controlled movement of the membrane hood within the lining and outer layer. 
     The location of the waterproof breathable membrane hood  7  between the lining  6  and the outer layer  5  typically means that its wrinkled or corrugated conformation is not apparent from a visual inspection of the outside of the hat, giving the hat a typical or traditional visual appearance. 
     In addition to the conformation of the waterproof breathable membrane hood allowing the hood  7  to expand as the outer layer  5  and lining  6  are stretched, its conformation and attachment also enable it to remain expanded when the hat is being worn by a user, thus rendering the hat comfortable when being worn and waterproof and heat insulating in use. 
     The waterproof breathable membrane hood can comprise bonded layers pressed together using a high temperature sealing machine or a high frequency plastic bonding machine (welder). 
     The present invention also provides a method of manufacturing a composite breathable elastic hat in which one of a lining  6  or outer layer  5  of the hat is stretched over a die  8 , mould or former, a waterproof breathable membrane hood  7  is then positioned over the lining  6  or outer layer  5  and another of an outer layer  5  or lining  6  is stretched over the waterproof breathable membrane hood  7 . The lining  6  and/or the outer layer  5  are attached to the waterproof breathable membrane hood  7  to form a hat structure or laminate structure which on removal from the die, mould or former contracts until the lining  6  and outer layer  5  are in a relaxed condition and the waterproof breathable membrane hood  7  is located therebetween in a wrinkled, puckered or corrugated conformation. 
     The waterproof breathable membrane hood  7  is positioned over the lining  6  in a relaxed, non-stretched condition and adhesive is applied to one or more of the lining  6 , outer layer  5  and waterproof breathable membrane hood  7  at discrete spaced locations, typically prior to layering. The adhesive can be applied by spotting, dusting, taping or other suitable means to provide discrete, spaced areas of adhesive on the respective lining  6 , outer layer  5  and/or waterproof breathable membrane hood  7 , to provide for attachment of at least one of the lining  6  and outer layer  5  to the waterproof breathable membrane hood  7 . In certain embodiments adhesive is added so that both the lining  6  and the outer layer  5  are each adhered to the waterproof breathable membrane hood  7 . 
     The adhesive may be a thermoset adhesive that is melted or softened on the die to adhere to the lining  6  and/or waterproof breathable membrane hood  7  and/or outer layer  5  together. The multifunction sandwich layer may be stitched to hold the multifunction sandwich layer together. 
     The invention further provides a composite waterproof breathable elastic hat, and a method of manufacturing such a hat in which a bi-layer is first formed of a lining or outer layer attached to a waterproof breathable membrane hood. The lining or outer layer is elastic or stretchy whereas the waterproof breathable membrane hood is non-elastic or substantially non-elastic. 
     The lining or outer layer in such bi-layers are attached to the waterproof breathable membrane in the same or similar manner discussed above so that when the bi-layer is removed from a mould or die the bi-layer contracts until the lining or outer layer is in a relaxed condition and the waterproof breathable membrane hood is attached to the lining in a wrinkled, puckered or corrugated conformation. 
     To form a hat from the bi-layer the other of an outer layer or lining is attached to the bi-layer off the die, so in the case where the bi-layer is formed of a lining (relaxed) and a waterproof breathable membrane hood in its relaxed condition then an outer layer is secured to the other side of the membrane hood to form a three layer lining. In such embodiments the lining, waterproof breathable membrane hood and outer layer are secured together generally by stitching through the lining and outer layer typically along the edge or edges over the lining to form a hat. The stitching may or may not extend through the waterproof breathable membrane, but in embodiments where it does, this is typically in areas where any detriment to the waterproof nature of the hat is of no practical detriment. 
     It will of course be appreciated that in those embodiments where the bi-layer comprises an outer layer and a waterproof breathable membrane, then a lining is attached to form the hat structure, with the waterproof breathable membrane between the lining and the outer layer. 
     The invention also provides a hat structure for a composite waterproof breathable hat or from which a composite waterproof breathable hat can be made. The hat structure comprises an elastic outer layer or elastic lining and a non-elastic or substantially non-elastic waterproof breathable membrane hood attached to an attachment surface of the lining or outer layer. 
     The waterproof breathable membrane hood may be attached to the lining or outer layer as described above. 
     The invention also provides a die, mould or former  8  for the manufacture of a composite waterproof breathable elastic hat or hat structure as described above, in which the die  8  comprises a forming surface on which the hat or hat structure is formed, the forming surface being arranged and dimensioned to receive and form the waterproof breathable membrane hood in its relaxed condition. 
     The die comprises a flat plate die with the same flat dimensions as the waterproof breathable membrane hood  7 . 
     The following are specific examples of the invention&#39;s implementation: 
     A waterproof breathable elastic knitted hat as shown in  FIG. 3 , including a knitted outer layer ( 5 ), knitted or elastic fabric lining ( 6 ), and a waterproof breathable membrane hood ( 7 ). This waterproof breathable membrane hood ( 7 ) is attached to the exterior of the hat lining ( 6 ) using a compound die ( 8 ), so that the waterproof breathable membrane hood ( 7 ) and the hat lining ( 6 ) form a single complex structure serving as a multi-function sandwich layer inserted between the lining and outer layers of the hat. The outcome is that without any loss of beauty in appearance or comfort in use the hat as described is rendered completely seamless and breathable and is wind and water proof. 
     Another example of the invention&#39;s implementation: 
     A waterproof breathable elastic knitted hat as shown in  FIG. 3 , including a knitted outer layer ( 5 ), a knitted or elastic fabric lining ( 6 ), and a waterproof breathable membrane hood ( 7 ). This waterproof breathable membrane hood ( 7 ) is attached to the inner surface of the hat&#39;s outer layer ( 5 ) using a compound die ( 8 ), so that the waterproof breathable membrane hood ( 7 ) and the hat&#39;s outer layer ( 5 ) forms a single complex structure serving as a multi-function sandwich layer inserted between the inner (lining) and outer layers of the hat. The outcome is that without any loss of beauty in appearance or comfort in use the hat as described is rendered completely seamless and breathable and is wind and water proof. 
     Another example of the invention&#39;s implementation: 
     A waterproof breathable elastic knitted hat as shown in  FIG. 3 , including a knitted outer layer ( 5 ), a knitted or elastic fabric lining ( 6 ), and a waterproof breathable membrane hood ( 7 ). This waterproof breathable membrane hood ( 7 ) is attached to the outside surface of the hat&#39;s lining ( 6 ) and the inner surface of the hat&#39;s outside layer ( 5 ) using a compound die ( 8 ), so that the waterproof breathable membrane hood ( 7 ) and the hat&#39;s lining ( 6 ) and hat&#39;s outer layer ( 5 ) together form a hat with a complex structure. 
     A specific example of the implementation of the compound die introduced by this invention for the processing of a compound waterproof breathable elastic knitted hat: 
     As shown in  FIGS. 4A-4C  the waterproof breathable membrane hood ( 7 ) which forms the multifunction sandwich layer for the waterproof elastic knitted hat has the same dimensions as the compound die plate ( 8 ), while being bigger than the flat dimensions of the hat&#39;s lining ( 6 ) to which it is attached. 
     An example of the processing method introduced in this invention to make a compound waterproof breathable elastic knitted hat: 
     As shown in FIGS.  3  and  4 A- 4 C, the hat&#39;s lining ( 6 ), after stretching to a structure like  FIG. 4A , is slipped over the compound die ( 8 ), and after being attached to the hood ( 7 ) by hot pressure takes on a structure like  FIG. 4B . When the hat is removed from the compound die ( 8 ), the elastic hat lining ( 6 ) shrinks back, and causes the compound sandwich layer to shrink back to a structure like  FIG. 4C , the result being that the slightly larger waterproof breathable membrane hood ( 7 ) takes on a crinkled wrinkled (which can also be described as puckered or corrugated) structure, in its natural state. This gives it the property of being stretchable in all directions, so that when worn on the head it is comfortably elastic. 
     To sum up, this invention introduces a compound waterproof breathable elastic hat and the die and process used to make it. The hat has an outer layer and a lining with elastic properties and a waterproof breathable membrane hood. This hood is attached to the exterior of the hat&#39;s lining and/or the interior of the hat outer layer with the use of a compound die, and in consequence the hood is combined into a single structure with at least the hat&#39;s lining or the hat&#39;s exterior layer. As a result, it has no ill effects on the hat&#39;s beauty of appearance or comfort in use, the hat is made seamless, windproof, waterproof and breathable, and the hood is given all-round elasticity without slipping and without noise. 
     Although the examples of implementation given above show some technical possibilities they should not be taken to limit this invention&#39;s scope of protection. Ordinary technicians in this field can improve and make changes to the implementation described without violating the essence and scope of the invention.