U.S. patent application number 16/432853 was filed with the patent office on 2019-09-19 for flexible fit cap with memory foam headband.
This patent application is currently assigned to Top of the World, LLC. The applicant listed for this patent is Top of the World, LLC. Invention is credited to Peter Wilson.
Application Number | 20190281917 16/432853 |
Document ID | / |
Family ID | 67904415 |
Filed Date | 2019-09-19 |
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United States Patent
Application |
20190281917 |
Kind Code |
A1 |
Wilson; Peter |
September 19, 2019 |
Flexible Fit Cap with Memory Foam Headband
Abstract
A cap configured to be worn on a wearer's head includes a crown
characterized by a substantially elliptical opening that has a
circumference and one or more radii normal to the circumference, a
bill connected to the crown, and a substantially elliptical
sweatband connected to the crown. The sweatband has a front portion
that is compliant in a radial direction and a back portion that is
flexible in an axial direction. The front portion includes a front
contact layer configured to be in contact with the wearer's head, a
concealed backing layer adjacent to the crown, and a compliant
layer between the front contact layer and the concealed backing
layer. The compliant layer is compliant in the radial direction.
The back portion has a rear contact layer configured to be in
contact with the wearer's head and a concealed support layer.
Inventors: |
Wilson; Peter; (Norman,
OK) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Top of the World, LLC |
Norman |
OK |
US |
|
|
Assignee: |
Top of the World, LLC
Norman
OK
|
Family ID: |
67904415 |
Appl. No.: |
16/432853 |
Filed: |
June 5, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
14462168 |
Aug 18, 2014 |
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16432853 |
|
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61867084 |
Aug 18, 2013 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A42B 1/248 20130101;
A42C 5/02 20130101 |
International
Class: |
A42C 5/02 20060101
A42C005/02; A42B 1/24 20060101 A42B001/24 |
Claims
1. A cap configured to be worn on a wearer's head, the cap
comprising: a crown, wherein the crown is characterized by a
substantially elliptical opening that has a circumference and one
or more radii normal to the circumference; a bill connected to the
crown; and a substantially elliptical sweatband connected to the
crown, wherein the sweatband comprises: a front portion that is
compliant in a radial direction, wherein the front portion
comprises: a front contact layer configured to be in contact with
the wearer's head; a concealed backing layer adjacent to the crown;
and a compliant layer between the front contact layer and the
concealed backing layer, wherein the compliant layer is compliant
in the radial direction; and a back portion that is flexible in an
axial direction, wherein the back portion comprises: a rear contact
layer configured to be in contact with the wearer's head; and a
concealed support layer.
2. The cap of claim 1, wherein the concealed support layer of the
back portion of the sweatband is construed from an elastic
material.
3. The cap of claim 2, wherein the back portion of the sweatband is
flexible in biaxial directions.
4. The cap of claim 1, wherein the compliant layer comprises
low-resilience polyurethane foam.
5. The cap of claim 3, wherein the compliant layer is configured to
adapt to heat produced by the wearer's head.
6. The cap of claim 5, wherein the compliant layer is configured to
soften and mold to the wearer's head in response to heat produced
by the wearer's head.
7. The cap of claim 1, wherein the crown comprises a plurality of
gores, wherein one or more of the plurality of gores are
manufactured from fabric that has lateral and longitudinal
elasticity.
8. The cap of claim 7, wherein the rear contact layer of the back
portion of the sweatband is manufactured from fabric that has
lateral and longitudinal elasticity.
9. The cap of claim 8, wherein the rear contact layer of the back
portion of the sweatband is manufactured from the same fabric that
is used to manufacture the one or more of the plurality of
gores.
10. The cap of claim 9, wherein the front contact layer of the
front portion of the sweatband is manufactured from the same fabric
that is used to manufacture the one or more of the plurality of
gores.
11. The cap of claim 1, wherein the front portion includes diamond
quilted stitching through the first contact layer, compliant layer
and backing layer.
12. The cap of claim 1, wherein the front portion and back portion
are connected by a seam cover.
13. A cap configured to be worn on a wearer's head, the cap
comprising: a crown, wherein the crown is characterized by a
substantially elliptical opening that has a circumference and one
or more radii normal to the circumference; a bill connected to the
crown; and a substantially elliptical sweatband connected to the
crown, wherein the sweatband comprises: a front portion adjacent to
the bill, wherein the front portion is compliant in a radial
direction; and a back portion connected to the front portion,
wherein the back portion is biaxially flexible in a circumferential
direction.
14. The cap of claim 13, wherein the front portion comprises: a
front contact layer configured to be in contact with the wearer's
head; a concealed backing layer adjacent to the crown; and a
compliant layer between the front contact layer and the concealed
backing layer, wherein the compliant layer is compliant in the
radial direction.
15. The cap of claim 13, wherein the back portion comprises: a rear
contact layer configured to be in contact with the wearer's head;
and a concealed support layer.
16. The cap of claim 15, wherein the concealed support layer of the
back portion of the sweatband is construed from an elastic
material.
17. The cap of claim 13, wherein the compliant layer comprises
low-resilience polyurethane foam.
18. The cap of claim 1, wherein the front portion and back portion
are connected by a seam cover.
19. A cap configured to be worn on a wearer's head, the cap
comprising: a crown, wherein the crown is characterized by a
substantially elliptical opening that has a circumference and one
or more radii normal to the circumference; and a substantially
elliptical sweatband connected to the crown, wherein the sweatband
comprises: a front portion that comprises: a front contact layer
configured to be in contact with the wearer's head; a concealed
backing layer adjacent to the crown; and a compliant layer between
the front contact layer and the concealed backing layer, wherein
the compliant layer is compliant in a radial direction; and a back
portion connected to the front portion, wherein the back portion
comprises: a rear contact layer configured to be in contact with
the wearer's head; and a concealed elastic support layer.
20. The cap of claim 19, wherein the rear contact layer and the
concealed elastic support layer are both flexible in biaxial
directions.
Description
RELATED APPLICATIONS
[0001] The present application is a continuation of U.S. patent
application Ser. No. 14/462,168 entitled "Headwear System" that was
filed on Aug. 18, 2014, which claims the benefit of U.S.
Provisional Patent Application Ser. No. 61/867,084, filed Aug. 18,
2013, entitled "Flexible Fit Cap with Memory Foam Sweatband," the
disclosures of which are herein incorporated by reference.
SUMMARY
[0002] In some aspects, exemplary embodiments include a cap that is
configured to be worn on a wearer's head. The cap includes a crown
characterized by a substantially elliptical opening that has a
circumference and one or more radii normal to the circumference, a
bill connected to the crown, and a substantially elliptical
sweatband connected to the crown. The sweatband has a front portion
that is compliant in a radial direction and a back portion that is
flexible in an axial direction. The front portion includes a front
contact layer configured to be in contact with the wearer's head, a
concealed backing layer adjacent to the crown, and a compliant
layer between the front contact layer and the concealed backing
layer. The compliant layer is compliant in the radial direction.
The back portion has a rear contact layer configured to be in
contact with the wearer's head and a concealed support layer.
BRIEF DESCRIPTION OF DRAWINGS
[0003] FIG. 1 illustrates a portion of an example headwear system
configured in accordance with some embodiments.
[0004] FIG. 2 is a cross-section view of an example headwear system
arranged in accordance with various embodiments.
[0005] FIG. 3 shows a cross-section view of an example headwear
system configured in accordance with assorted embodiments.
[0006] FIGS. 4A-4D respectively display different views of portions
of an example headband that may be utilized in a headwear system in
accordance with some embodiments.
[0007] FIG. 5 conveys a top view of a portion of an example
headwear system configured in accordance with various
embodiments.
[0008] FIG. 6 is a block representation of a portion of an example
headwear system arranged in accordance with assorted
embodiments.
[0009] FIG. 7 provides a flow chart of an example headwear
utilization routine that may be carried out in accordance with some
embodiments.
[0010] FIG. 8 is bottom view of a baseball cap constructed in
accordance with another embodiment.
[0011] FIG. 9 is a bottom view of the baseball cap of FIG. 8.
[0012] FIG. 10 is a partial cut-away view of the sweatband of the
baseball cap of FIG. 8.
[0013] FIG. 11 is a cross-sectional view of the front portion of
the sweatband of FIG. 10.
[0014] FIG. 12 is a cross-sectional view of the back portion of the
sweatband of FIG. 10.
[0015] FIG. 13 is a partial cut-away view of an alternate
embodiment of the sweatband of FIG. 8.
[0016] FIG. 14 is a cross-sectional view of the sweatband of FIG.
13.
DETAILED DESCRIPTION
[0017] Various embodiments of the present disclosure generally
relate to structure and function of a headwear system. Items of
headwear, such as sports caps, visors, and headbands, can be
symbols of fashion. However, due to different people's heads being
different shapes and sizes, it can be difficult to properly fit
headwear, which can be detrimental to a person's fashion. The
ability to customize headwear can complement properly fitting
headwear to optimize a person's fashion. Hence, headwear configured
to properly fit a user while providing customizable features is a
consumer and industry interest.
[0018] Accordingly, assorted embodiments configure a headwear
system with a headband that fits a head of a user. At least one
compliant portion is attached to the headband with a fastener. The
compliant portion temporarily conforms to the head of the user in
response to being positioned on the user's head. A medallion can be
affixed to a bill extending from the headband and be arranged to
extend through an aperture in an information feature that is also
affixed to the bill. The compliant portion can allow headwear to
fit a diverse variety of head shapes and sizes. The ability to
customize the position of the medallion on the bill can allow a
user to configure the headwear for various fashion styles and
preferences.
[0019] FIG. 1 shows an example headwear system 100 arranged in
accordance with various embodiments to provide a properly fitting
headband 102 and a bill 104 that can be customized. As shown, the
headwear system 100 is constructed as a sports cap, such as a
baseball hat, that is defined by a body 106 that is constructed of
one or more gores meeting at a crown 108. The gores of the body 106
may be any shape, size, orientation, and material, which gives the
headband 102 a size and shape. It is contemplated that the headband
102 and body 106 are configured to be flexible, rigid, or a
combination of the two to facilitate comfort, fashion, and
universal fitment.
[0020] Although the bill 104 can be manipulated and formed into a
variety of different shapes due to its semi-rigid construction,
various embodiments incorporate at least one information feature
110 that adheres to the bill 104 and conveys an unlimited amount of
information. As a non-limiting example, the information feature 110
can be graphics, logos, text, braille, and holographics that can
convey information about the headwear system 100, such as a sports
team, a charitable organization, and advertising. The information
feature 110 can be shaped to cover some or substantially all of at
least one surface of the bill 104, such as having a shape that
matches the shape of the bill 104, to provide a large curvilinear
or planar surface to convey information. The ability to tune the
information feature 110 for size, shape, and material allows
information to be efficiently and prominently displayed to others
for a variety of purposes, such as fashion and information
pertinent to selling the headwear system 100 to a user.
[0021] While the information feature 110 can provide fashion for
some users, some embodiments configure the feature 110 to be
removable by providing an adhesive portion that can allow the
feature 110 to be selectively removed and moved at will. That is,
portions of the information feature 110 can have adhesive that
temporarily attaches the feature 110 to the bill 104 and allows the
feature 110 to be moved to any region of the bill 104 or body 106.
The ability to remove and relocate the information feature 110 can
be also provided in a medallion 112 that continuously extends
through an aperture 114 in the information feature 110. The
medallion 112 can be any size, shape, material, and position on the
bill 104 or body 106.
[0022] In some embodiments, the medallion 112 is a rigid material
resembling a logo, which may represent a company, sports team,
fictional character, and slogan without limitation. The combination
of the medallion 112 and information feature 110 can allow multiple
different fashion, advertising, and information to be conveyed
concurrently. However, a user may not like the size or information
conveyed on either the information feature 110 or medallion 112.
Accordingly, the medallion 112 and information feature 110 can be
removed individually without altering the position of the other
aspect. For example, the aperture 114 allows the information
feature 110 to be removed from the bill 104 without disturbing the
medallion 112.
[0023] FIG. 2 displays a cross-sectional view of an example
headwear system 120 configured in accordance with some embodiments
to provide a headband 122 that continuously and circumferentially
extends around an inner region 124 defined by a body 126. A bill
128 extends from the body 126 and has an information feature 130
and medallion 132 concurrently displayed on an exterior surface
134. It is contemplated that the information feature 130, medallion
132, or additional adhesive aspects can be attached to an interior
surface 136 of the bill 128, which may enhance fashion and safety
in various headwear system 120 applications.
[0024] The headband 122 can be constructed in an unlimited variety
of fixed, flexible, and adjustable sizes. For instance, the
headband 122 can sized to be a predetermined diameter, flexible to
a variety of different diameters, and adjustable through a fastener
system to a selected diameter. With the diverse variety of head
sizes, hair styles, and comfort, a user may find the headband 122
unsatisfactory despite the ability to flex and adapt to a user's
head. It is contemplated that a flexible headband 122 can be too
constrictive for some users and lose its elasticity through trauma
and use. Therefore, various embodiments configure the headband with
a compliant portion that conforms to a user's head with optimized
comfort, longevity, and customization.
[0025] FIG. 3 shows a cross-section view of an example headwear
system 140 that is constructed and operated in accordance with
various embodiments. The headwear system 140 has a body 142 that
defines an inner region 144 that is partially or completely
surrounded by a headband 146. A bill 148 continuously extends from
the body 142 and has a medallion 150 positioned on an exterior
surface 152. It is noted that the bill does not have an information
feature, such as feature 110 of FIG. 1, but can be assumed that an
information feature was previously present and removed from the
bill, or not ever present.
[0026] The headband 146 can be configured with any combination of
rigid, flexible, and semi-rigid materials that are layered or
individually presented to predetermined portions of the headband
146. In accordance with some embodiments, a compliant portion 154
of the headband 146 can be positioned proximal the bill 148 and
provide material that conforms to a user's head, such as cloth or
foam, with minimal pressure applied to the head, which contrasts
elastic, flexible headbands that can apply too little or too much
pressure that results in an uncomfortable experience for a
user.
[0027] Various embodiments incorporate the compliant portion 154
into the headband 146 by being sewn into a cloth or elastic strip,
as shown in FIG. 3, while other embodiments configure the compliant
portion 154 to be an additional component that can be attached in
any position around the headband 146. The ability to tune the
configuration of the compliant portion 154 for position, material,
and presentation in relation to a user's head allows the headwear
system 140 to be customized for fit and fashion. For example, the
compliant portion 154 may be tuned to allow the headwear system 140
to be securely and comfortably worn in non-traditional manners,
such as backwards, sideways, and tilted. Such secure and
comfortable fitment can be attributed to the default or customized
position and configuration of the compliant portion 154. That is,
the compliant portion 154 may be removed, replaced, and reattached
in different locations that can provide optimized fitment for a
virtually any user's head.
[0028] In an example embodiment, the headband 146 is configured
with a compliant portion 154 that continuously extends around the
entire circumference of the body 142 and has different thicknesses,
as measured from the internal surface 156 of the body 142 towards a
center of the headband 146 along the Z axis. The different headband
146 and compliant portion 154 thicknesses can be positioned at
locations that traditionally receive pressure and induce
discomfort, such as along the temporal and forehead regions of a
user's head. The compliant portion 154 may further be configured
with a memory foam material construction, such as a low resilience
polyurethane foam, that deforms in response to contact with a
user's head and subsequently returns to a different default shape
once the headwear system 140 is removed from the user's head.
[0029] FIGS. 4A-4D respectively illustrate different views of an
example compliant portion 160 configured in accordance with various
embodiments to be permanently or temporarily incorporated into a
headwear system. FIG. 4A shows a top view of the compliant portion
160 that has a tuned shape and size to continuously extend around
some, but not all, of the circumference of a headband, as
represented by segmented line 162. The compliant portion 160 is
configured with a thickness 164 that may be uniform or varying
throughout the compliant body 166. A separate second compliant
portion 167 can be positioned on the headband. It is contemplated
that the compliant portion 160 can have a diameter 168 that is the
same as the headband. It is further contemplated that the compliant
portion may be interconnected into a continuous circular, or
spheroid, shape by attaching two ends of the compliant body 166 via
a seam cover 170.
[0030] The tuned size and position of the compliant portion 160 in
a headband can allow the headband to conform to the user's head
while maintaining rigidity through the portions of the headband
that do not contain material that deforms to conform to the user's
head. In other words, the compliant body 166 can have a size and
shape that is selected in relation to the overall construction of
the headband to provide secure and comfortable fitment with a
user's head while providing rigidity that maintains the headwear
system in place, particularly during movement of the user.
[0031] FIG. 4B is a side view block representation of the compliant
portion 160 that shows how the compliant body 166 can be shaped to
provide a carrier portion 172 with a uniform thickness along the Y
axis that is disposed between connection tabs 174. The carrier
portion 172 and tabs 174 can each be constructed of an elastic
material that applies pressure to a foam insert 176 to induce the
foam insert 176 to contact a user's head and deform when worn. The
carrier portion 172 has a length 178 that is greater than the
length 180 of the foam insert 176, but such configuration is not
limiting as the foam insert 176 may continuously or discontinuously
extend beyond the carrier length 178, such as into the tabs
174.
[0032] It is noted that various portions of the compliant portion
160 can have one or more fastening means attached thereto. For
example, but in no way limiting, hook-and-loop, magnets, and
adhesives can be positioned on various locations on the compliant
portion 160 to allow for selective installation and removal from a
headband. Some embodiments configure the connection tabs 174 to
fasten together to form a loop, such as with the aid of a seam
cover 170. The tuned size and shape of the connection tabs 174 can
allow the compliant portion 160 to be easily attached, removed, and
repositioned anywhere on a headband to provide customizable fitment
for a headwear system.
[0033] FIG. 4C displays a cross-section view block representation
of the compliant portion 160 that illustrates how the foam insert
176 can consist of a number of different layers that can be
horizontally stacked along the Z axis or vertically stacked along
the X axis. As shown, the compliant body 166 is shaped to present
the connection tabs 174 to allow efficient installation and removal
of the compliant portion 160 along any portion of a headband, such
as within a headband flap. It is understood that the foam insert
176 may deform and present uncomfortable undulations in the
headband. Accordingly, the foam insert 176 is configured with an
overall thickness 182 that compensates for deformation of the first
184 and second 186 foam layers to provide a uniform headband
surface that aligns the carrier 188 and foam 190 surfaces along the
Z axis when the compliant portion 160 is worn, as depicted in FIG.
4D.
[0034] Through various embodiments, the foam insert 176 can have
any number of dissimilar layers that are tuned to provide optimized
fitment without being bulky, heavy, or awkward. That is, the first
foam layer 184 can be constructed with a different density, weight,
material, and thickness than the second foam layer 186. For
example, the first foam layer 184 may have a lower density than the
second foam layer 186 to allow more efficient heat dissipation from
the user's head while providing pressure-sensitive deformation in
response to contact with the user's head. It is contemplated that
the combination of different foam layers 184 and 186 can provide
optimized headband fitment by presenting multiple different
structures that deform and react to a user's head differently.
[0035] FIG. 5 is a top view of a portion of an example headwear
system 200 that has a plurality of medallions and information
feature positioned on a bill 202. It is to be understood that any
number of similar and dissimilar medallions and information
features can be incorporated into the headwear system 200. The
non-limiting embodiment shown in FIG. 5 illustrates how a first 204
and second 206 information features can be separated by a seam 208
and arranged with mating surfaces 210 that correspond and form a
single comprehensive information structure. Such comprehensive
information structure can convey an unlimited variety of graphics
and text that can be easily manipulated by removing one information
feature while leaving another information feature on the bill
202.
[0036] Regardless of the number and subject matter on the
information features 204 and 206, at least one medallion can extend
through an aperture 212 in the information feature. A first
medallion 214 is configured with a first shape and size that
differs from the configurations of the second 216, third 218, and
fourth 220 medallions. The different shapes of the medallions 214,
216, 218, and 220 are not required or limiting, but show how
differently configured medallions and apertures 212, such as
squares, parallelograms, rhomboids, octagons, and trapezoids, can
be incorporated into the headwear system 200 and aligned along any
longitudinal axis, such as axis 222 that is angled with respect to
the Z and X axes. Various embodiments configure the various
medallions to have shapes and sizes that can interconnect and form
a collective image, shape, or design in response to a user removing
and repositioning at least one medallion.
[0037] FIG. 6 displays a cross-section view block representation of
a portion of an example headwear system 230 configured in
accordance with some embodiments to have a bill 232 on which an
information feature 234 and medallion 236 are respectively
attached. It is noted that the bill 232 has a uniform thickness 238
along the Y axis, but such configuration is not required as a
varying thickness may allow the bill 232 to be controlled and
manipulated more easily. The information feature 234 is configured
as a lamination of a fastener layer 240, such as an adhesive,
hook-and-loop, magnetic, or tongue-and-groove fastener, and an
exterior layer 242 that collectively have a information thickness
244. The information feature has an information surface 246 that is
opposite the bill 232 and conveys graphics and text that may be
printed, imprinted, and holographically projected.
[0038] The medallion 236 is also configured with a fastener layer
248 that contacts the bill 232 and positions the exterior layer 250
to face away from the bill 232. The various layers of the
information feature 234 and medallion 236 can be tuned to have
different thicknesses 244 and 252 that may convey texture and
design that are fashionable and eye-catching. As shown the
medallion 236 extends a certain distance 254 above the information
feature 234, such as 1 cm, through the aperture 256. The ability to
manipulate the fastening means and thicknesses of the information
feature 234 and medallion 236 can convey a diverse variety of
textures, graphics, and text that can be selectively removed,
reorganized, and reattached at the will of the user to produce
customized headwear.
[0039] FIG. 7 is a flow chart of an example headwear utilization
routine 260 that may be conducted in accordance with various
embodiments to provide customized and comfortable headwear.
Initially, step 262 attaches a compliant portion to a headband.
Step 262 may be a permanent attachment, such as stitching the
compliant portion into the headband, or a temporary attachment
where the compliant portion can be subsequently removed or
repositioned by a user to optimize comfort and fitment. Step 264
then positions at least one information feature and medallion on
the bill of the headwear.
[0040] Although the user may wear the headwear with the information
feature and medallion attached to the bill, various embodiments
conduct step 266 where at least one information feature is removed
while the medallion is unaltered. Next, decision 268 determines if
the medallion is to be moved. A decision to move the medallion
advances routine 260 to step 270 where the medallion is
repositioned on a selected portion of the bill, such as the
exterior or interior surfaces of the bill. At the conclusion of the
customization of the medallion placement in step 270, or if the
medallion is maintained at its original location, step 272
subsequently positions the headwear on the head of a user in a
manner that deforms the compliant portion to provide a secure and
comfortable fit of the headband.
[0041] It is noted that the various steps and decision of routine
260 are not required or limiting. As such, any aspect of routine
260 can be changed and removed just as any number of decisions and
steps can be added. For example, additional steps may follow step
270 to reposition a plurality of medallions in a collective
configuration that may extend into the body of the headwear.
[0042] Referring to FIG. 8, shown therein is a cap 500 constructed
in accordance with an alternate embodiment of the present
invention. The cap 500 includes a crown 502 constructed from a
plurality of substantially triangular gores 504. It will be
understood that the crown 502 is adequately shaped and sized to
receive the wearer's head. The cap 500 also includes a bill 506
that extends from the front of the crown 502. As shown, the bill
506 is slightly contoured in a parabolic fashion. Although the
present invention as described herein is embodied within the cap
500, it will be understood that the present invention can also be
applied to other forms of headwear including, but are not limited
to, cowboy hats and berets.
[0043] In the presently preferred embodiment, the crown 502 is
preferably constructed from a material that permits a flexible fit
to adjust to the unique size of the wearer's head. To enable
lateral stretching about the circumference of the crown 502, as
indicated by arrows 508, an elastic fiber is woven into the weft of
the material selected to construct the gores 504. Similarly, if a
longitudinal flex is desired, an elastic fiber can be woven into
the warp of the material used to construct the gores 504. It will
be understood that the cap 500 can also be constructed to have both
lateral and longitudinal elasticity.
[0044] In another embodiment, the two front gores 504 are lined
with a semi-rigid backing that provides structure and shape to the
front of the crown 502. In this embodiment, it is not necessary
that the two front gores 504 be fabricated from a stretchable
material. In a particularly preferred embodiment the two front
gores 504 are provided with a buckram backing. Alternatively, all
of the gores 504 are manufactured without the rigid backing to
provide an unstructured cap 500.
[0045] Turning to FIG. 9, shown therein is a bottom view of the cap
500. As shown in FIG. 9, the cap 500 further includes a sweatband
510 that is circumferentially disposed about the inside of the
bottom edge of the crown 502. In the presently preferred
embodiment, the sweatband 510 includes an arcuate front portion 512
connected to an arcuate back portion 514 with a seam cover 516. As
explained herein, the back portion 514 is preferably constructed to
permit biaxial flexibility, while the front portion 512 provides a
degree of compliance and flexibility in a radial direction.
[0046] Referring to FIG. 10, shown therein is a partial view of the
sweatband 510 in partial cut-away view constructed in accordance
with a first preferred embodiment. FIGS. 11 and 12 present
cross-sectional views of the front portion 512 and back portion
514, respectively. The back portion 514 includes a rear contact
layer 520 attached to a concealed elastic support layer 522. The
bottom edges of the rear contact layer 520 and elastic support
layer 522 are attached to the lower perimeter of the crown 502. The
top edges of the rear contact layer 520 and elastic support layer
522 are preferably not sewn to the inside surface of the crown
502.
[0047] The front portion 512 of the sweatband 510 preferably
includes an exposed front contact layer 524, a concealed backing
layer 526 and an intermediate foam layer 528. The backing layer 526
can be attached at its top and bottom edges to the mating top and
bottom edges of the front contact layer 524 with stitching 530. The
lower edges of the front contact layer 524 and backing layer 526
are collectively joined with the lower edge of the crown 502. In an
alternate preferred embodiment, the backing layer 526 is not
included in the front portion 512. In the presently preferred
embodiment, the rear contact layer 520, front contact layer 524 and
backing layer 526 are constructed from a breathable polyester
fabric that exhibits good durability.
[0048] In a particularly preferred embodiment, the rear contact
layer 520, front contact layer 524 and backing layer 526 are
constructed from the same material that is used to fabricate the
gores 504. As such, the rear contact layer 520, front contact layer
524 and backing layer 526 can be constructed from scrap or other
portions of the same material used to construct the gores 504,
thereby providing a lower cost of manufacture. Unlike similar prior
art sweatbands, however, the rear contact layer 520 is not created
by simply folding a portion of the gores 504 inside the crown 502.
As such, the rear contact layer 520 does not include gore seams or
gore reinforcements that tend to create uncomfortable lumps in the
sweatband 510.
[0049] The elastic support layer 522 is preferably constructed from
thin elastic webbing or spandex. The elastic support layer 522
provides additional structure to the rear contact layer 520 without
inhibiting the overall circumferential flexibility of the sweatband
510. In an alternate preferred embodiment, the elastic support
layer 522 is not included in the back portion 514.
[0050] The intermediate foam layer 528 is preferably constructed
from a low-resilience polyurethane foam. Suitable foam layers may
include those products referred to as "memory foam." In a
particularly preferred embodiment, the intermediate foam layer 528
is manufactured from a higher-density memory foam that softens in
reaction to heat from the wearer's head, thereby allowing it to
mold to a warm body in a few minutes. In an alternative embodiment,
the intermediate foam layer 528 is constructed from a lower-density
foam that is pressure-sensitive and molds quickly to the shape of
the wearer's head pressing against it, returning to its original
shape once the pressure is removed.
[0051] The intermediate foam layer 528 does not present a high
degree of stretching in the axial directions, but provides the
sweatband 510 with an additional degree of flexibility in the
radial direction. By compressing in response to pressure and heat
exerted by the wearer's head, the intermediate foam layer 528
allows the sweatband 510 to comfortably conform to a larger number
of head sizes. The ability for a single size cap 500 to comfortably
conform to a larger number of heads presents a significant advance
over the prior art. Moreover, the combination of the axially
stretchable back portion 514 with the radially compliant front
portion 512 provides a sweatband 510 and cap 500 that is
comfortable to wear and is securely fitted to the wearer's head,
but does not create irritation or marking on the wearer's
forehead.
[0052] As shown in FIG. 10, the front portion 512 and the back
portion 514 of the sweatband 510 are preferably connected with the
seam cover 516. The seam cover 516 is preferably rectangular in
shape, having a first side connected to the front portion 512 and
an opposed second side connected to the back portion 514. To reduce
the thickness of the sweatband 510, it is preferred that the front
portion 512 and back portion 514 not overlap. However, to
facilitate manufacture, it may be desirable to slightly overlap the
front and back portions 512, 514 before affixing the seam cover
516.
[0053] It is also preferred that the seam cover 516 have a low
profile above the sweatband 510 and be manufactured from a thin
piece of fabric that is tear and wear resistant. Suitable fabrics
include polyester and nylon blends. In an alternative embodiment,
the seam cover 516 can be fabricated from a flexible material that
stretches when subjected to a tensile load from the front portion
512 and back portion 514. It will be noted that the seam cover 516
can also be used to display a logo or design.
[0054] Turning to FIGS. 13 and 14, shown therein are partial
cut-away and cross-sectional views, respectively, of an alternate
embodiment of the front portion 512 of the sweatband 510. In the
alternate embodiment depicted in FIG. 8, the front portion 512
includes diamond quilted stitching 532 that extends through the
front contact layer 524, intermediate foam layer 528 and backing
layer 526. The diamond quilted stitching 532 generally decreases
the tendency of the intermediate foam layer 528 to "bulge" through
the front contact layer 524 and backing layer 526 and presents an
attractive sweatband 510.
[0055] Through the various embodiments of a headwear system,
comfort and customization are optimized to provide a unique and
fashionable article. The tuned configuration of a compliant portion
of a headband can provide material that deforms to conform to the
shape and size of a user's head, which increases fitment of the
headwear as well as allowing secure non-traditional headband
orientations. The incorporation of at least one information feature
and medallion on a bill or body of the headwear system can provide
advertising and fashion components that can be selectively removed
and reorganized to convey a customized, fashionable appearance.
[0056] Numerous characteristics and advantages of various
embodiments of the present disclosure have been set forth in the
foregoing description, together with structural and functional
details. Nevertheless, this detailed description is illustrative
only, and changes may be made in detail, especially in matters of
structure and arrangements of parts within the principles of the
present disclosure to the full extent indicated by the broad
general meaning of the terms in which the appended claims are
expressed.
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