Improvements in the Manufacture of Hats.
Year: 1899

page_text: PROVISIONAL SPECIFICATION.
Improvements in the Manufacture of Hats.
I, JOHN HENRY NEAVE, of Rainow, Macclesfield, in the County of Chester,
England, Manufacturer, do hereby declare the nature of this invention to be
as follows:
This invention has reference to an improved hat in imitation of a felt hat,
and to the process of making the same the objects being to produce a hat which
will be inexpensive, durable and of light weight, and which will have the
appearance of the ordinary felt hat so commonly worn. The invention consists
in forming the body of the hat of a mixture of pulp and a resinous material in
granular or pulverulent form treated to form a homogeneous or substantially
homogeneous mass and covering this body with fur or analogous material to
produce a surface resembling that of a felt hat.
In carrying my invention into effect, I first form from a mixture of pulp,
preferably wood pulp and a resinous material in granular or pulverulent form
à body of the general form of the hat to be made, which operation may be con-
veniently effected by apparatus consisting of a tank containing in its base a
perforated hat form of the construction well known in the art, and a pipe for
withdrawing the water through the form. A mixture of wood pulp and a resinous
material, preferably shellac, in granular or pulverulent form as distinguished
from a solution of the same, is placed in the tank above the perforated hat form
and the water of the mixture being withdrawn from below through the pipe
a layer or deposit of the mixture and shellac will be left on the surface of the
form producing a pulp body. This layer is removed from the form and sub-
jected to pressure in any suitable manner to consolidate the mass and expel the
water therefrom. It is then dried and subjected to the action of a sufficient
degree of heat to melt the shellac, the result being that the melted shellac will
run or flow and permeate the fibres of the pulp and form a practically homo-
geneous integral mass or body. This pulp body is now ready to receive on its
surface the coating of fur or analogous material to cause it to resemble the ordi-
nary felt hat. The fur is applied by bringing it in a concentrated or condensed
condition into intimate contact with the surface of the body, to which an adhe-
sive composition has been applied, the result being the adhesion of the fur in a
uniform layer completely covering the surface of the body and producing a
surface resembling that of felt. I prefer to accomplish the condensation or con-
centration of the fur to enable it to be brought in this condition into contact
with the pulp body, by depositing a layer of the fur on a flexible backing, in an
ordinary perforated hat form such as was employed to form the pulp body.
This may be accomplished by the same apparatus on the tank of which a
mixture of water and fur in a finely divided condition is introduced the perfora-
ted form being first covered by the felt cap or backing. On the withdrawal
of the water through this backing and form, the fur will be deposited on the
backing in a uniform layer. The water is then drained from the fur, prefer-
.

page_text: ably by placing the backing with the fur thereon in a hydraulic press and sub-
jecting the same to high pressure, and after the fur is thoroughly dried by heat
or otherwise it is ready to be applied to the pulp body. Before applying the
fur to the pulp body the surface of the latter is coated with an adhesive com-
position to cause the fur to adhere. I prefer to employ a varnish for this pur-
pose, and in order to prevent the alcohol in the varnish from acting on the pulp
or shellac in the body, which would interfere with the adhesive action of the
varnish, I propose to first coat the body with a size of such a nature as to
resist the action of the alcohol. The backing with the fur thereon is now
applied to the pulp body with the fur surface next the varnished surface of the
pulp body, and they are subjected to the action of heat and pressure conve-
niently in a heated metal die, the result being that the varnish and shellac will be
softened by the heat, and the fur being thus brought into intimate contact with
the softened varnish will be caused to adhere to the surface of the body forming
a uniform layer of fur completely and wholly covering the surface of the pulp
body. When the varnish has set, the cap or backing is stripped leaving the fur
coating exposed. By thus applying the fur coating by bringing the fur in a
condensed or concentrated condition into contact with the pulp body, I am
enabled to obtain a thicker and more uniform layer on the body, than if the fur
were sifted or dusted on as has hitherto been practiced.
Instead however of first depositing a layer of the fur on the backing as des-
cribed, it may be compressed around the hat in a suitable casing surrounding
the hat. The fur being packed in this casing is brought in a compressed con-
dition into intimate contact with the body and caused to adhere as in the other
case described.
It is to be understood that while I prefer to form the body of the hat of a
mixture of pulp and resinous material deposited by suction upon a perforated
shape the body of the hat may be formed of pulp alone so deposited or it may
be composed of pulp or other material formed to the desired shape in any other
convenient manner and then covered by a coating or covering of compressed or
condensed fur in imitation of felt placed over and caused to adhere thereto.
The hat may now be subjected to such of the usual finishing and polishing
operations as are commonly practiced and which may be found necessary to
give the surface a smooth and finished appearance to resemble that of the ordi-
nary felt hats and the interior of the hat may be treated to give it the proper
finished appearance.
A condensed fur covering similar to that applied to the exterior of the hat
may be prepared in a similar mould and inserted in the interior, the three
layers being then compressed together and thus giving to the interior of the
hat an appearance of imitation felt.
By forming the body of pulp and shellac or of any other resinous or gummy
material, the body is readily susceptible to the action of heat so that the brim
may be properly curled and the crown manipulated to properly fit the wearer,
as the usual felt hats are now shaped to the head.
Dated this 16th day of March 1899
WM. P. THOMPSON & Co.,
6, Bank Street, Manchester, Patent Agents.
WM. P. THOMPSON & Co.,
6, Bank Street, Manchester, Patent Agents.
COMPLETE SPECIFICATION.

page_text: ner the same is to be performed, to be particularly described and ascertained
in and by the following statement:-
This invention has reference to an improved hat in imitation of a felt hat,
and to the process of making the same the objects being to produce a hat which
shall be inexpensive durable and of light weight and which shall have the
appearance of the ordinary felt hat so commonly worn.
This invention consists in forming the body of the hat of pulp or other light
or fibrous material stiffened to the desired degree and blocked to shape and
encasing this body with a covering of consolidated or condensed fur to produce
a surface resembling that of a felt hat.
or other pulp and a
pulverulent form to
Or the pulp may be
coated with a heavy
The pulp may be prepared of a mixture of fibrous wood
resinous material such as resin or shellac in granular or
provide a homogeneous or practically homogeneous mass.
employed alone to form the hat body or shape and then be
solution of shellac or resinous material which is caused to penetrate into or be
absorbed into the pulp by heat.
In the accompanying drawing:-
The figure is a sectional elevation of a tank with a perforated hat form therein
for the purpose of producing pulp body of the hat."
In carrying my invention into effect I first form from pulp (preferably a
mixture of pulp and a resinous material in granular or pulverulent form) a
body of the general form of the hat to be made which operation may be con-
veniently effected by apparatus consisting of a tank 1 containing in its base
a perforated hat form 2 of the construction well known in the art and a pipe 3
for withdrawing the water through the form.
The pulp or a mixture of pulp and a resinous material preferably shellac in
granular or pulverulent form as distinguished from a solution of the same is
placed in the tank above the perforated hat form and the water of the mixture
being withdrawn from below through the pipe a layer or deposit of the pulp
or the pulp and shellac will be left on the surface of the form producing a pulp
body. This layer is removed from the form and subjected to pressure in any
suitable manner to consolidate the mass and expel the water therefrom. It is
then dried and when mixed with shellac subjected to the action of a sufficient
degree of heat to melt the shellac the result being that the melted shellac will
run or flow and permeate the fibres of the pulp and form a practically homo-
geneous integral mass or body. This pulp body is now ready to receive on its
surface the coating of fur or analogous material to cause it to resemble the
ordinary felt hat.
When pure pulp is used the hat body is coated with a heavy solution of
shellac or other resinous material and then heated to cause the shellac to per-
meate the fibres of the pulp.
The fur is applied by bringing it in a concentrated or condensed condition
into intimate contact with the surface of the body to which an adhesive com-
position has been applied the result being the adhesion of the fur in a uniform
layer completely covering the surface of the body and producing a surface
resembling that of felt.
I prefer to accomplish the condensation or concentration of the fur to enable
it to be brought in this condition into contact with the pulp body by depositing
a layer of the fur on a flexible backing in an ordinary perforated hat form such
as was employed to form the pulp body.
This may be accomplished by the same apparatus represented in the drawing
in the tank 1 of which a mixture of water and fur in a finely divided condition
is introduced the perforated form 2 being first covered by the felt cap or back-
ing. On the withdrawal of the water through this backing and form, the fur
will be deposited on the backing in a uniform layer. The water is then drained
from the fur preferably by placing the backing with the fur thereon in a
hydraulic press and subjecting the same to high pressure and after the fur is

page_text: thoroughly dried by heat or otherwise it is ready to be applied to the pulp body:
Before applying the fur to the pulp body the surface of the latter is coated with
an adhesive composition to cause the fur to adhere. I prefer to employ a varnish
for this purpose and in order to prevent the alcohol in the varnish from acting on
the pulp or shellac in the body which would interfere with the adhesive action
of the varnish, I prefer to first coat the body with a "size of such a nature as
to resist the action of the alcohol. The backing with the fur thereon is now
applied to the pulp body with the fur surface next the surface of the pulp body
and they are subjected to the action of heat and pressure conveniently in a heated
metal die, the result being that the varnish and shellac will be softened by the
heat and the fur being thus brought into intimate contact with the softened
varnish will be caused to adhere to the surface of the body forming a uniform
layer of fur completely and wholly covering the surface of the pulp body. When
the varnish has set the cap or backing is stripped leaving the fur coating ex-
posed. By thus applying the fur coating by bringing the fur in a condensed
or concentrated condition into contact with the pulp body I am enabled to obtain
a thicker and more uniform layer on the body than if the fur were sifted or
dusted on as has hitherto been practiced.
Instead however of first depositing a layer of the fur on the backing as des-
cribed it may be compressed around the hat in a suitable casing surrounding
the hat. The fur being packed in this casing is brought in a compressed con-
dition into intimate contact with the body and caused to adhere as in the other
case described.
"
It is to be understood that while I prefer to form the body of the hat of a mix-
ture of pulp and resinous material deposited by suction upon a perforated shape
the body of the hat may be formed of pulp alone so deposited or it may be com-
posed of pulp or buckram or other stiffened canvas or other material blocked
or formed to the desired shape in any other convenient manner and then
covered by a coating or covering of compressed or condensed fur in imitation
of felt placed over and caused to adhere thereto.
The hat may now be subjected to such of the usual finishing and polishing
operations as are commonly practiced and which may be found necessary to give
the surface a smooth and finished appearance to resemble that of the ordinary
felt hats and the interior of the hat may be treated to give it the proper finished
appearance.
A condensed fur covering similar to that applied to the exterior of the hat
may be prepared in a similar mould and inserted in the interior the three layers
being then compressed together and thus giving to the interior of the hat an
appearance of imitation felt. By forming the body of pulp and shellac or of
any other resinous or gummy material the body is readily susceptible to the
action of heat so that the brim may be properly curled and the crown manipu-
lated to properly fit the wearer as the usual felt hats are now shaped to the head.
Having now particularly described and ascertained the nature of my said
invention and in what manner the same is to be performed, I declare that what
I claim is:
1. A hat consisting of a body of any suitable material formed to the desired.
shape and covered with an external covering or coating of consolidated or con-
densed fur to resemble felt substantially as described.
2. A hat consisting of a stiff body of pulp formed to the shape of a hat and
covered with a cap or covering of fur resembling felt condensed or consolidated
to the same form and drawn over and caused to adhere to the stiff body sub-
stantially as described.
3. A hat consisting of a body of pulp and solidified resinous material con-
solidated together with an external covering or coating of fur resembling felt
applied in a condensed or consolidated form substantially as described.

page_text: 4. The process of manufacturing hats resembling felt which consists in pro-
ducing a body in the general form of a hat by depositing pulp on a shape and
when dry and stiff applying to the said body a flexible backing having a layer
of condensed and consolidated fur thereon with the fur next the hat-body and
finally stripping off the backing leaving the condensed fur as a covering or
surface for the hat resembling felt substantially as described.
5. The process of manufacturing hats resembling felt and hats as described.
Dated this 9th day of November 1899.
WM. P. THOMPSON & Co.,
Manchester, Liverpool, & London, Patent Agents.
WM. P. THOMPSON & Co.,
Manchester, Liverpool, & London, Patent Agents.