IMPROVE. MENTS IN THE MANUFACTURE OF HELMETS, HATS, AND OTHER COVERINGS FOR THE HEAD
Year: 1877

page_text: LETTERS PATENT to Charles Vero and James Everitt, both of Atherstone, in
the County of Warwick, Hat Manufacturers, for the Invention of "IMPROVE.
MENTS IN THE MANUFACTURE OF HELMETS, HATS, AND OTHER COVERINGS FOR
THE HEAD."
Sealed the 20th October 1877, and dated the 26th May 1877.
1
PROVISIONAL SPECIFICATION left by the said Charles Vero and James
Everitt at the Office of the Commissioners of Patents on the 26th May 1877.
CHARES VERO and JAMES EVERITT, both of Atherstone, in the County of
Warwick, Hat Manufacturers. IMPROVEMENTS IN THE MANUFACTURE OF HELMETS,
HATS, AND OTHER COVERINGS FOR THE HEAD."
"
In the Specifications of former Patents granted to one of us (namely Charles Vero)
in the year 1868, Numbers 1547 and 2907, was described various ways of making
double-bodied hats and other coverings for the head and pressing them to form in
heated moulds.
In one way of making such hats the inner body was coated with ordinary
hatters' proofing, and when the outer covering had been placed over it, the two
were pressed together in a heated mould by a hatter's hydraulic bag press, as is well
understood.
Another way for making soft hats was to interpose sheet gutta percha between
the inner body and outer covering, and press the whole together in the same way
in a heated mould. In both these ways it was necessary that the mould should be
heated in order to secure the union of the parts of which the hat was formed, but by
reason of the hats being in a heated state when taken from the moulds it was
difficult to keep them to the form given to them, and for this and other reasons
such ways of making hats were not practically successful.
According to our present Invention we are enabled to make double-bodied
helmets, hats, and other coverings for the head without any of the disadvantages
attending the manufacture of hats in the ways above described.

page_text: To manufacture a double-bodied felt helmet, we take a body formed in the
ordinary manner of felt and lightly proofed; or it may be a body of cloth, satin, or
other material; this we block on a helmet-shaped block, and apply to it one or
more coatings of india-rubber or such like solution, which when dry will form a
flexible membrane. We then take thin sheet cork cut to forms required, and which
has been coated on one side with india-rubber or such like solution, and apply the
pieces to the body; they may either be applied to the crown only, or to the entire
surface of the body. We then again coat the body with india-rubber or such like
solution, and in some cases place over it either paper or woven fabric, which has
been first proofed with ordinary proofing solution, and afterwards with india-
rubber or such like solution. We now take an outer cover of felt, cloth, silk, plush,
or other cover, which has been previously coated on the inside with india-rubber or
such like solution, and strain it over the body whilst its surface is still wet with
india-rubber solution. The helmet is then stoved and dried; afterwards its edges
are pared, and finally when it has been heated in an oven it is placed into a metal
mould, and hydraulic pressure applied in the manner before mentioned, whereby the
helmet is caused to assume the shape of the mould, and quickly becomes set in that
shape, as when the helmet is: formed in the manner above described the metal
mould does not require to be heated. The helmet is then finished in the ordinary
manner as required.
Hats and other coverings for the head may be formed in a similar manner.
When cork is applied only to the upper part of a hat or other covering, we
apply stiff proofing to the lower part of the inner body forming the brim and band,
so that whilst the upper part is flexible, the lower part is comparatively rigid, and
can be shaped in the usual manner.
In order also to enable hats or helinets to withstand heavy blows, we place within
them a number of arched strips of spring steel, which pass across the interior of the
body and bear against it, whilst at their ends the springs are received in sockets
carried by an inner band, which is to encircle the head, and which is securely
attached to the interior of the helmet or hat. By this means a kind of dome-
shaped structure of spring steel is formed within the interior of the helmet.
Other ways than that above described may also be adopted for retaining the ends
of the spring strips.
The strips may also in some cases be corrugated or indented at intervals;
and another spring wire may be coiled spirally around the dome-shaped spring
structure, and lie in the indentations of the arched springs.

page_text: SPECIFICATION in pursuance of the conditions of the Letters Patent filed
by the said Charles Vero and James Everitt in the Great Scal Patent Office on
the 26th November 1877.
CHARLES VERO and JAMES EVERITT, both of Atherstone, in the County of
Warwick, Hat Manufacturers. "IMPROVEMENTS IN THE MANUFACTURE OF HELMETS,
HATS, AND OTHER COVERINGS FOR THE HEAD."
The object of our improvements is so to construct the bodies of helmets, hats, and
other coverings for the head (that let them be covered by whatever material,
whether woven felted silk, plush, leather, grasses, straw, or chips) as to give them
much greater strength and resistance, not only to the weather, but also in cases
where required, as for military and police, or for hunting caps, against sword cuts, or
brickbats, or falling from horseback; as also to improve the external appearance of
the coverings and the exactness of their conformation, and also to render their
brims, or that portion that is used for taking the helmet or hat on and off the head,
of a strength suitable to this requirement, and capable of taking the proper curves
and curls to any degree of rigidity, and not as hitherto, where bodies have been
constructed of alternate layers of cork, or in combination with other materials
stiffened over all their parts with india-rubber solution alone, and as a consequence
soft and flabby to the touch, and insusceptible to take either curls or curves, and
hence useless where lightness and smartness of appearance is requisite.
To manufacture a double-bodied helmet, we take by preference a light felt body
slightly stiffened with ordinary hard proofing of any color, but green is most suitable
for helmets, and steam on to the blocks of any required shape. We then take a
piece of felt or gossamer stiffened to any desired strength by the ordinary shellac
proofing, as is well understood, without any crown or head piece, and we steam this
over the foundation felt to cover the brim part, and reach about one inch up the
side crown; when this is cold we slip it off the lower foundation and trim it level
with a knife as required for the band (or if preferred this steaming of the brim can
be done on a larger block). We then solution the under side of the brim all over
with india-rubber solution, herein-after called "solution," and we also solution the
foundation body all over. We then place the brim of felt or gossamer over the
foundation on the brim part, pressing them firmly together, and allow them to dry.
When dry we further trim the edge of the felt or gossamer at the band, and
solution over the felt brim at the band. We then take thin sheets of cork that
have been properly solutioned and attach them to the foundation felt, and let them
overlap the felt brim at the band, and coat over the outside of the cork again with
solution; when sufficiently dry we put on other layers of sheet cork, paper, woven
fabrics that have been stiffened, as required, with ordinary proofing, and afterwards
solutioned over with india-rubber solution according to the degree of flexibility-
required. We then clean the surface of the body and make it level; after it is dry
we take it off the block, and having placed the body into an ordinary hatter's oven or
baker, we place it in a mould, such mould by preference being cold, of the required
shape, and subject it to hydraulic pressure, as is well understood. This not only con-
solidates the body, but presses the seams or other inequalities in the inside of the
body; we then take out the pressed body, and solution it completely; and the
cover, if of felt, being also by preference lightly proofed, is turned on the wrong side
and solutioned over; it is then turned back and pulled over the body on the block
already solutioned, and being thoroughly adhered in all its parts, is put in the stove
to dry; after which it is finished on its surface and re-pressed; the brim being cut
to the required shape, it is trimmed in the ordinary manner. Though felt covering
is described, all materials would be so made; and in case of cloth or other material,
which is cut in segments, the hydraulic pressure would so press them into the body
that the surface would be smooth and level.

page_text: Another improvement consists in covering helmets and the crowns of hats with
two pieces only of felt, or cloth, or woven or texile fabrics. To effect this we take
a piece of cloth, and having placed it on the cross, we strain over one side of the
helmet block and frame till it passes a line drawn from front to rear through the
centre helmet, and we securely nail it to the block beyond the line indicated (if the
cloth or fabric is very stubborn and strong we use steam to assist in taking
the shape); when dry we brush, if necessary, a slight coating of albumen in
solution sufficiently thick not to penetrate the cover to its right side. When this is
dry we coat it ever with india-rubber solution, and place it in the stove to dry. It
will then keep its shape, and by cutting in the line directed from front to rear of
helimet, and attaching to the solutioned body two equal parts, the one seam only is
made by leaving more cloth; a sewn seam can be made if preferred, and the cover
pulled over and treated as though it was seamless felt.
Although we have described the felt of gossamer brim as being separate from the
foundation, we can of course stiffen the lower portion of the brim and band of the
foundation body to any required degree; and if desired we can also carry
the sheet cork over the top side of brim as well as over the crown.
In place
of using it over the crown only, as previously described, sometimes we leave the
sheet cork from the crowns altogether, and cover over in the manner already
explained the felt body with felt or other fabrics, the foundation and cover being
proofed with proofing solution, and afterwards being caused to adhere together with
india-rubber solution in the manner above described.
We have named a felt foundation, as this has many advantages for helmets, being
an absorbent, but when it is desired to have appearance for an inside lining, we
should use a foundation of satin or other suitable material.
Also according to our Invention we strengthen and render waterproof hats and
other coverings for the head, the bodies of which are composed of straw, grass, chips,
or such like materials:
That class of hats or head coverings made of such materials have hitherto been
stiffened and held in their shape by albumen, and useless to resist weather except
when covered by waterproof materials. By our Invention this is obviated; we'
solution the inside of straw or such like hats with india-rubber solution, and take a
felt body of any colour or strength, and may be proofed all over, or partly so, and
solution that, and place one over the other, and allow them to dry, and then press
or finish them in the ordinary way.
Cork, satin, cloth, or other suitable materials may be substituted for felt, and
used in the same manner. The combination of the two modes thus effected renders
the hat waterproof, and its shape is preserved without any stiffening in the straw,
&c., but stiffening may be used if desired.
To give greater strength and resistance to hats, helmets, and other coverings for
the head where required, as for helmets for inilitary and police, as a protection
against sword cuts, blows from sticks, brickbats, and such like, or to hunting caps,
we strengthen the body of the hat, helmet, or other covering for the head by
incorporating within the body, that is, between the layers of which the body is
composed, wires or strips of steel, or other metal covered with a fibrous covering,
coiled, or braided, or otherwise formed around it.
We prefer to place the strips or wires in spiral coils around the body leading from
tho centre of the top of the body, where there is usually a metal ventilating pieco
or ornament, and passing downwards in successive coils to the brim.
If two coils are used we prefer that the coils should be in opposite directions, só
that the coils cross one another at numerous points.
When the wires or strips covered, as above described, are interposed between
two of the layers forming the body of the helmet, hat, or other covering for the
head, the india-rubber or such like cementing solution, by which the layers are to
be cemented together, as above described, will adhere firmly to the fibrous covering
of the wires or strips, and hold then securely in place; whereas if the wires or

page_text: strips were uncovered no such secure hold could be obtained, but every movement
of the wires or strips would tend to sever the connection between the two parts of
the body. We apply the covered wires or strips to the exterior of the inner portion
of the body whilst it is supported on a block, and after its exterior. has been coated
with india-rubber, or such like solution; the covered wires or strips are then coiled
around it, and will when pressed against the coated surface be held and retained
in place sufficiently to allow of the next layer or covering of the body to be placed
over it in segments. The segments having been previously coated internally with
india-rubber solution, as before described, will adhere firmly to the inner portion of
the body, and securely enclose the covered wires or strips.
India-rubber solution should also be applied to the fibrous covering of the wires
or strips.
In place of the covered wires or strips being coiled around the body they might
be led radially from the centre of the top of the body to a metal band around the
lower part of the body, or such radial strips or wires may be used together with the
coiled wires or strips. When covered wires or strips have thus been introduced
into the body of a hat, helmet, or other covering for the head, and the body is
afterwards pressed in a hatter's hydraulic bag press, the wires or strips will be
firmly embedded into the material of the body, and thus great strength will be
obtained both vertically and horizontally, and consequently safety to the wearer from
injuries in any direction.
In a similar way to that above described the interior of all kinds of flexible hats,
or other coverings for the head with flexible crowns, may be retained in shape by
flexible metal wires or strips covered with fibrous material; such wires or strips
being placed within the interior of the body, and held thereto by an internal lining
cemented thereto with india-rubber or such like solution.
Having thus described the nature of our Invention and the manner of performing
the same, we would have it understood that we claim as our improvements in the
manufacture of helmets, hats, and other coverings for the head,-
First. Making the bodies of hats or helmets with an inner layer or foundation of
felt (whether the felt is proofed or not) covered with layers of cork, woven or
textile fabrics, or with bodies of woven grass, chips, straw, or such like materials, and
afterwards covered with felt, cloth, silk, plush, or textile fabrics, the several layers
being held together with india-rubber solutions or solutions of a like nature,
substantially as described.
Second. Making the above-named compound bodies with a brim and band part
of felt or gossamer stiffened with ordinary shellac proofing to any degree of rigidity,
leaving the crowns flexible, substantially as herein-before described.
Third. Making the above-named compound bodies on felt foundations with the
brim and band parts proofed to a sufficient strength to render unnecessary the use
of an additional gossamer or felt brim.
Fourth. The manufacture of bodies for hats, helmets, and other coverings for the
head from layers of cork, textile fabrics, or paper stiffened with shellac or its
equivalents, and covered or coated with india-rubber or such like solutions, and
cemented together, substantially as herein described.
Fifth. Strengthening and supporting the bodies of hats, helmets and other
coverings for the head with flexible wires or strips of metal covered with fibrous
material, interposed between the layers of which the body is composed, and which
are cemented together, as herein-before described.
Sixth. The covering of helmets, or hats of any kind, instead of as heretofore with
a number of segments, with two pieces of cloth or material, whereby only one seam
is made, and stitching rendered unnecessary, or only on one seam, as may be
desired.
Seventh. The application to head coverings of straw, chips, Brazilian grass,or
other such like head coverings, of a lining of felt, stiffened or not, cloth, satin, or
any other suitable material attached to the said hats by india-rubber solution.
Eighth. The manufacture of bodies for hats, helmets, and other coverings for the

page_text: head from layers of material stiffened with shellac or equivalent proofing, cemented
together with india-rubber or such like solution, and pressed in a hatter's hydraulic
press, substantially as described.
In witness whereof, I, the said Charles Vero, have hereunto set my hand and
seal, this Twenty-sixth day of November, in the year of our Lord One
thousand eight hundred and seventy-seven.
CHARLES VERO. (L.S.)
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