Environmentally-Friendly Visor Stiffening Member and Manufacturing Method Thereof

Abstract

An environmentally-friendly visor stiffening member and a manufacturing method thereof may provide a smoothly curved shape without using an environmentally-bad plastic material and being easily sewn. The environmentally-friendly visor stiffening member is sandwiched with at least one fabric piece layer, an adhesive resin layer disposed under the fabric piece layer, and a pulp or cellulose board layer disposed under the fabric piece layer via the adhesive resin layer. With this structure, the visor portion may have a smoothly curved shape even though it is not made of an environmentally-bad synthetic resin material, it may not be easily ruptured even if excessive force is applied thereto, and it may be easily sewn to provide a beautiful aesthetic appearance.

1 . A environmentally-friendly visor stiffening member sandwiched with at least one fabric piece layer, an adhesive resin layer disposed under the fabric piece layer, and a pulp or cellulose board layer disposed under the fabric piece layer via the adhesive resin layer. 
   
   
       2 . The environmentally-friendly visor stiffening member of  claim 1 , wherein the adhesive resin layer is composed of an environmentally-friendly water-soluble adhesive and is indirectly heated via the fabric piece to be softened and hardened to curve the visor stiffening member. 
   
   
       3 . The environmentally-friendly visor stiffening member of  claim 2 , wherein the adhesive resin layer includes a rosin ester that has a softening point of 75 to 120° C. as a main component, and contains abietic acid of the chemical formula C 20 H 30 O 2  at equal to or less than 3.0% as a white crystal and dehydroabietic acid at below 15%. 
   
   
       4 . The environmentally-friendly visor stiffening member of  claim 3 , wherein the adhesive resin layer contains oxygen at equal to or less than 0.3% and impurities of equal to or less than 0.04%. 
   
   
       5 . The environmentally-friendly visor stiffening member of  claim 1 , wherein the cellulose or pulp board has a thickness of about a 1.50±0.5 mm and a density of 0.72±0.20 g/cm 3 . 
   
   
       6 . The environmentally-friendly visor stiffening member of  claim 5 , wherein the cellulose or pulp board has a peel strength of equal to or more than 0.3 kN/m, a strain strength of equal to or more than about 0.5 kN/cm 2  for a submerging test, and a bending strength of equal to or more than 1.9. 
   
   
       7 . A method for manufacturing an environmentally-friendly visor stiffening member, comprising:
 supplying a fabric piece having a hardened adhesive resin layer of a thickness of about 0.05±0.02 mm on at least one surface thereof and a cellulose or pulp board in a sandwiched sheet;   cutting the fabric piece and the cellulose or pulp board in correspondence with a shape of a visor portion protruding outward from at least a part of a crown portion of a headwear to shield sunlight;   softening the adhesive resin layer by indirectly heating the same via the fabric piece or the cellulose or pulp board with the cellulose or pulp board being smoothly curved along a curve forming portion by a thermal forming unit having a recess portion and the curve forming portion;   curing and setting the sandwiched fabric piece or the cellulose or pulp board via the softened adhesive resin layer in a curved state by a cooling unit.   
   
   
       8 . The method for manufacturing an environmentally-friendly visor stiffening member of  claim 7 , further comprising heating the recess portion and the curve forming portion to a temperature 120 to 180° C. by a heating portion, and maintaining a protrusion portion and a curve forming portion of the cooling unit at a temperature of 25° C. 
   
   
       9 . The method for manufacturing an environmentally-friendly visor stiffening member of  claim 8 , wherein the adhesive resin layer includes a rosin ester that has a softening point of 75 to 120° C. as a main component, and contains abietic acid of the chemical formula C 20 H 30 O 2  as a white crystal at equal to or less than 3.0% and dehydroabietic acid at below 15%. 
   
   
       10 . The method for manufacturing an environmentally-friendly visor stiffening member of  claim 9 , comprising supplying a subsidiary material having a melting point of equal to or more than about 180° C. between the curve forming portion and the recess portion. 
   
   
       11 . The method for manufacturing an environmentally-friendly visor stiffening member of  claim 10 , wherein the cellulose or pulp board has a thickness of about a 1.50±0.5 mm and a density of 0.72±0.20 g/cm 3 . 
   
   
       12 . The method for manufacturing an environmentally-friendly visor stiffening member of  claim 11 , wherein the cellulose or pulp board has a peel strength of equal to or more than 0.3 kN/m, a strain strength of equal to or more than about 0.5 kN/cm 2  for a submerging test, and a bending strength of equal to or more than 1.9. 
   
   
       13 . A headwear comprising a crown portion that is placed on the head and a visor portion protruding outward from at least a part of the crown portion to shield sunlight, wherein the visor portion includes a sandwiched environmentally-friendly visor stiffening member surrounded by an upper fabric piece and a lower fabric piece thereof and the environmentally-friendly visor stiffening member is sandwiched with at least one fabric piece layer, an adhesive resin layer disposed under the fabric piece layer, and a pulp or cellulose board layer disposed under the fabric piece layer via the adhesive resin layer. 
   
   
       14 . The headwear of  claim 13 , wherein the adhesive resin layer is composed of an environmentally-friendly water-soluble adhesive and is indirectly heated via the fabric piece to be softened and hardened to curve the visor stiffening member. 
   
   
       15 . The headwear of  claim 14 , wherein the adhesive resin layer includes a rosin ester that has a softening point of 75 to 120° C. as a main component, and contains abietic acid of the chemical formula C 20 H 30 O 2  at equal to or less than 3.0% as a white crystal and dehydroabietic acid at below 15%. 
   
   
       16 . The headwear of  claim 15 , wherein the adhesive resin layer contains oxygen at equal to or less than 0.3% and impurities of equal to or less than 0.04%. 
   
   
       17 . The headwear of  claim 13 , wherein the cellulose or pulp board has a thickness of about a 1.50±0.5 mm and a density of 0.72±0.20 g/cm 3 . 
   
   
       18 . The headwear of  claim 17 , wherein the cellulose or pulp board has a peel strength of equal to or more than 0.3 kN/m, a strain strength of equal to or more than about 0.5 kN/cm 2  for a submerging test, and a bending strength of equal to or more than 1.9.