Abstract:
The self-sizing baseball cap with a two or more piece, one or more layer sweatband satisfies the long recognized need of providing a baseball cap that fits a range of head sizes comfortably without any wearer adjustable cap sizing devices. This sweatband is flexibly attached to the self-sizing baseball cap so that it can be in either the stowed or deployed position when wearing the cap. When deployed, it creates an expanded self-adjustable attachment area on the wearer&#39;s head and provides more shade and warmth to the wearer. The two or more piece, one or more layer sweatband can be made from one or more than one different material with some or all materials biaxially or uniaxially stretchable. Each piece of the sweatband can be a different color or the same color as the other sweatband pieces.

Description:
This appln claims benefit of Prov. No. 60/260,988 filed Jan. 11, 2001. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to an improved construction of a baseball cap, capable of fitting wearers having a plurality of head sizes. The cap includes a crown portion fabricated from a multi-gore shell, a visor portion connected to the front of the crown portion, and a two or more piece, and one or more layer sweatband. The stowable or deployable stretchable sweatband permits the cap to fit onto the head of the wearer without uncomfortable circumferential pressure. 
     2. Description of Related Art 
     Visored or baseball type caps are well known in the art and come in many configurations. They include a hemispherical crown portion to fit onto a wearer&#39;s head and a visor or bill portion attached to the front of the hemispherical crown portion. Several substantially triangular panels called gores are joined together with seams to form the crown. 
     There are many different types of caps that have been available over the years with various wearer adjustable features in order to fit a plurality of head sizes. This type generally has an opening in the base of the crown portion opposite the visor at the back of the cap. The opening generally has overlapping straps that are adjustably attached to each other to change the circumferential cap size to accommodate a multitude of head sizes. While the base of the hemispherical portion may be enlarged to accommodate the larger sized head, there must be an aperture formed in the rear of the cap that the overlapping straps span so that the entire hat can expand to the degree necessary to fit the larger head. Therefore, the rear portion of the cap is not of a uniform construction and the forming of the opening or vent creates not only a loss of material but greater difficulty manufacturing the cap. 
     In most of the prior art caps that incorporate what might be considered stretchable fabric, the desired level of comfort and easy of use to the wearer has not been achieved. The cap causes undo compressive pressure around the head of the wearer thereby causing discomfort to the wearer and even resulting in the cap leaving a mark on the wearer&#39;s skin. 
     The present invention can be distinguished from U.S. Pat. No. 5,615,415, A Custom-fit Cap. “A custom-fit cap having a visor portion and a substantially hemispherical crown portion attached to the visor portion and at least a crown portion opposite the visor and covering the back of the head being formed of the material that stretches at least circumferentially about the crown portion for accommodating various head sizes. A band that is stretchable circumferentially and is attached to the inside of the hemispherical crown portion adjacent the base thereof forms a sweatband to engage the head of the user while allowing the cap to stretch circumferentially with at least that portion of the crown portion covering the back of the head opposite the visor, so as to enable the cap to self-adjust automatically to fit a plurality of head sizes.” The present invention incorporates a distinctive deployable or stowable two or more piece, one or more layer sweatband that can have one or more stretchable or all sections stretchable or some of the sections stretchable. When deployed the two or more piece, one or more layer sweatband allows for a self-adjustable expanded attachment area on the wearer&#39;s head and provides more shade and warmth to the wearer. The deployed two or more piece, one or more layer sweatband can be multiple colors, or a single color and it can match or be in contrast to the colors of the cap. U.S. Pat. No. 5,615,415 incorporates a one-piece non-deployable sweatband. 
     The present invention can be distinguished from U.S. Pat. No. 5,715,540, A Free-size cap. “A free-size cap is capable of fitting wearers having a range of head sizes. The cap includes a multi-gore shell forming a crown portion, and a visor or bill portion connected to the crown portion. Ones of the gores forming the multi-gore shell are composed of a uniaxially stretchable woven material capable of being stretched only along the chordial axis of said multi-gore shell. The free-size cap has the aesthetic appeal of a fixed-size style cap, being capable of custom fitting all wearers within a predetermined range of head sizes, without requiring an adjustable fastener portion or an open portion on the back of the cap. An advantage of this free-size cap is that it is capable of custom fitting all wearers within a predetermined range of head sizes, without the drawback of changes in shape due to differences in head size.” The present invention incorporates a distinctive deployable or stowable two or more piece, one or more layer sweatband that can have one or more stretchable or all sections stretchable or some of the sections stretchable. When deployed the two or more piece, one or more layer sweatband allows for a self-adjustable expanded attachment area on the wearer&#39;s head and provides more shade and warmth to the wearer. The deployed two or more piece, one or more layer sweatband can be multiple colors, or a single color and it can match or be in contrast to the colors of the cap. U.S. Pat. No. 5,715,540 incorporate a one-piece non-deployable sweatband and relies upon a confining uniaxially stretchable crown portion to provide adjustable fit. 
     The present invention can be distinguished from U.S. Pat. No. 5,966,742, An Adjustable Cap. “An adjustable cap has a crown portion shaped for fitting over the crown of a wearer&#39;s head, with the rear part of the crown portion formed of a stretchable material. A two part peripheral band is secured around the lower peripheral edge of the crown portion on the inside of the cap. The first, front part of the band is of a moisture absorbent, non-stretch material, and the second, rear part extending across the rear of the crown portion is of a stretchable material. The rear part of the band stretches to adjust the size of the peripheral opening to fit wearer&#39;s of differing head sizes.” The present invention incorporates a distinctive deployable or stowable two or more piece, one or more layer sweatband that can have one or more stretchable or all sections stretchable or some of the sections stretchable. When deployed the two or more piece, one or more layer sweatband allows for a self-adjustable expanded attachment area on the wearer&#39;s head and provides more shade and warmth to the wearer. The deployed two or more piece, one or more layer sweatband can be multiple colors, or a single color and it can match or be in contrast to the colors of the cap. U.S. Pat. No. 5,966,742 incorporates a two piece non-deployable sweatband and relies upon only a confining biaxially stretchable aft sweatband portion to provide adjustable fit. 
     An objective of the present invention is to overcome the disadvantages of the prior art by providing a custom-fit comfortable cap having no vent and no adjustable straps at the back thereof and yet which can accommodate a plurality of various sized heads. 
     It is still another important objective of the present invention is to provide a cap which has a self-adjustable expanded attachment area on the wearer&#39;s head and provides more shade and warmth to the wearer and the sweatband can be multiple colors, or a single color and it can match or be in contrast to the colors of the cap. 
     It is a further objective of the present invention to provide a baseball-type cap structure capable of multi-sizing in use, which can be manufactured easily utilizing conventional materials and fabrics, and which is both functional and attractive in its use and appearance. 
     It is still a further objective of the present invention to decrease the quantity of retail cap stock necessary to accommodate a plurality of various sized heads. 
     BRIEF SUMMARY OF THE INVENTION 
     The invention is a self-sizing baseball cap. The self-sizing baseball cap includes a plurality of fabric gores of substantially triangular shape. Each fabric gore has a first side, a second side and third side. A crown portion is created by attaching the first side of the gore to the second side of another adjacent gore and so forth until the creation of a closed section of essentially hemispherical shape. The crown portion has an inner surface and an outer surface and a lower peripheral edge. The lower peripheral edge has a forward portion, a forward midpoint, an aft portion, an aft midpoint and a circumferential linear perimeter of a first predetermined length. 
     A visor of an essentially rigid nature is attached to the forward portion of the lower peripheral edge. 
     A sweatband is provided. The sweatband is shaped as an elongated rectangle and has an upper edge, a lower edge, a first edge, a second edge, a forward sweatband midpoint and a first predetermined width. The sweatband is joined at its first edge and its second edge to form a continuous loop. 
     The sweatband is attached to the lower peripheral edge so that the forward sweatband mid point coincides with the forward midpoint and the aft sweatband midpoint coincides with the aft midpoint. 
     The attachment of the lower edge of the sweatband to the lower peripheral edge possesses a flexibility that permits the sweatband loop to be in the stowed or deployed position when wearing the self-sizing baseball cap. The stowed position has the outer surface of sweatband flush against the inner surface of the crown portion. The deployed position has the outer surface of the sweatband flush against the head of the wearer of the self-sizing baseball cap. 
     In a variation of the invention, the first predetermined length comes in a short and a long length to accommodate a range of head sizes comfortably. The short length is sized to fit small to medium size heads comfortably. The long length is sized to fit large to extra large size heads comfortably. 
     In another variation of the invention, the sweatband is created from two or more layers. Each layer is shaped as an elongated rectangle with an upper edge, a lower edge, a first edge, a second edge, an inner surface, an outer surface, and a first predetermined width. 
     The two or more layer sweatband has an inner layer and an outer layer. The outer surface of the inner layer being attached to the inner surface of the outer layer. 
     In yet another variation of the invention, each sweatband layer is made from different materials. 
     In still another variation of the invention, each sweatband layer is made from the same material. 
     In a different variation of the invention, the inner surface of the inner layer of the sweatband is made from a material that feels comfortable to a wearer during long term contact with the wearer&#39;s skin or hair. 
     In another different variation of the invention, the outer surface of the outer layer of the sweatband is made from a material that feels comfortable to a wearer during long term contact with the wearer&#39;s skin or hair. 
     In yet a different variation of the invention, each sweatband layer is either sweat absorbent or non-sweat absorbent. 
     In still a different variation of the invention, the inner layer is uniaxially stretchable. 
     In still another different variation of the invention, the inner layer is biaxially stretchable. 
     In distinctive variation of the invention, the outer layer is uniaxially stretchable. 
     In another distinctive variation of the invention, the outer layer is biaxially stretchable. 
     A second version of the invention is a self-sizing baseball cap. This self-sizing baseball cap includes a plurality of fabric gores of substantially triangular shape. Each fabric gore has a first side, a second side and third side. A crown portion is created by attaching the first side of the gore to the second side of another adjacent gore and so forth until the creation of a closed section of essentially hemispherical shape. The crown portion has an inner surface and an outer surface and a lower peripheral edge. The lower peripheral edge has a forward portion, a forward midpoint, an aft portion, an aft midpoint and a circumferential linear perimeter of a first predetermined length. 
     A visor of an essentially rigid nature is attached to the forward portion of the lower peripheral edge. 
     A sweatband is provided. The sweatband is created from two or more sweatband segments. Each sweatband segment is shaped as an elongated rectangle with an upper edge, a lower edge, a first edge, and a second edge and a first predetermined width. 
     The first edge of the sweatband segment is attached to the second edge of an adjacent sweatband segment and so forth to create a closed loop, two or more piece the sweatband. The sweatband has an inner surface, an outer surface and a circumferential linear extent of a first predetermined length. 
     The sweatband is attached to the lower peripheral edge so that the forward sweatband mid point coincides with the forward midpoint and the aft sweatband midpoint coincides with the aft midpoint. 
     The attachment of the lower edge of the sweatband to the lower peripheral edge possesses a flexibility that permits the sweatband loop to be in the stowed or deployed position when wearing the self-sizing baseball cap. The stowed position has the outer surface of sweatband flush against the inner surface of the crown portion. The deployed position has the outer surface of the sweatband flush against head of the wearer of the self-sizing baseball cap. 
     In a variation of the invention, the first predetermined length comes in a short and a long length to accommodate a range of head sizes comfortably. The short length is sized to fit small to medium size heads comfortably. The long length is sized to fit large to extra large size heads comfortably. 
     In yet another distinctive variation of the invention, each sweatband segment is a different color or the same color as the other the sweatband segments. 
     In still another distinctive variation of the invention, the sweatband segment is sweat absorbent. 
     In a discrete variation of the invention, a sweatband segment is non-sweat absorbent. 
     In another discrete variation of the invention, a sweatband segment is uniaxially stretchable. 
     In yet another discrete variation of the invention, a sweatband segment is biaxially stretchable. 
     In a distinguishable variation of the invention, each sweatband segment is made from different materials. 
     In another distinguishable variation of the invention, each sweatband segment is made from the same material. 
     In yet another distinguishable variation of the invention, each sweatband segment is created from two or more layers. Each sweatband segment layer is shaped as an elongated rectangle with an upper edge, a lower edge, a first edge, a second edge, an inner surface, an outer surface, and a first predetermined width. 
     The two or more layer sweatband segment has an inner layer and an outer layer. The outer surface of the inner layer is attached to the inner surface of the outer layer. 
     In still another distinguishable variation of the invention, each sweatband segment layer is made from a different material than another sweatband segment layer. 
     In a discernable variation of the invention, each sweatband segment layer is made from the same material. 
     In another discernable variation of the invention, the inner surface of the inner layer of the sweatband segment layer is made from a material that feels comfortable to a wearer during long term contact with the wearer&#39;s skin or hair. 
     In yet another discernable variation of the invention, the outer surface of the outer layer of the sweatband segment layer is made from a material that feels comfortable to a wearer during long term contact with the wearer&#39;s skin or hair. 
     In still another discernable variation of the invention, each sweatband segment layer is sweat absorbent or non-sweat absorbent. 
     In a hitherto discernable variation of the invention, the inner layer of each sweatband segment is uniaxially stretchable. 
     In another hitherto discernable variation of the invention, the inner layer of each sweatband segment is biaxially stretchable. 
     In yet another apparent variation of the invention, the outer layer of each sweatband segment is uniaxially stretchable. 
     In still another apparent variation of the invention, the outer layer of each sweatband segment is biaxially stretchable. 
     In another hitherto apparent variation of the invention, each sweatband segment layer is a different color or the same color as the other the sweatband segment layers. 
     Self-sizing baseball cap according to the present invention overcomes the aforementioned disadvantages of the known multi-size caps and of the fixed-size style caps. An advantage of the present invention is that it is capable of custom fitting all wearers within a predetermined range of head sizes without requiring an adjustable fastener portion or an open portion on the back of the cap. The invention meets the objective to provide a baseball-type cap structure capable of multi-sizing in use, which can be manufactured easily utilizing conventional materials and fabrics, and which is both functional and attractive in its use and appearance. A retailer only has to keep two sizes to be in stock small-medium and large-extra large. The present invention also has an aesthetic appeal over the adjustable strap open back type of caps. Further, the customer perceived quality of a self-sizing baseball cap versus hat styles that have manually adjustable sizes adds a great deal of customer perceived value and satisfaction with the cap. Also, the inventory of caps needed to meet consumer demands is substantially reduced. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an orthogonal view from the bottom looking upwards into the inside of the cap with the one or more layer sweatband in the stowed position; 
     FIG. 2 is an orthogonal view from the bottom looking upwards into the inside of the cap with the one or more layer sweatband in the deployed position. 
     FIG. 3 is an orthogonal view from the bottom looking upwards into the inside of the cap with the two or more piece, one or more layer sweatband in the stowed position; 
     FIG. 4 is an orthogonal view from the bottom looking upwards into the inside of the cap with the two or more piece, one or more layer sweatband in the deployed position. 
    
    
     DETAILED DESCRIPTION 
     As shown in FIGS. 1 and 2, the invention is a self-sizing baseball cap  10 . The self-sizing baseball cap  10  includes a plurality of fabric gores  14  of substantially triangular shape. Each fabric gore  14  has a first side  18 , a second side  22  and third side  26 . A crown portion  30  is created by attaching the first side  18  of the gore  14  to the second side  22  of another adjacent gore  14  and so forth until the creation of a closed section of essentially hemispherical shape. The crown portion  30  has an inner surface  34  and an outer surface  38  and a lower peripheral edge  40 . The lower peripheral edge  40  has a forward portion  44 , a forward midpoint  48 , an aft portion  52 , an aft midpoint  56  and a circumferential linear perimeter of a first predetermined length. 
     A visor  64  of an essentially rigid nature is attached to the forward portion  44  of the lower peripheral edge  40 . 
     A sweatband  68  is provided. The sweatband  68  is shaped as an elongated rectangle and has an upper edge, a lower edge  74 , a first edge  76 , a second edge  80 , a forward sweatband midpoint  84  and a first predetermined width  88 . The sweatband is joined at its first edge  76  and its second edge  80  to form a continuous loop. 
     The sweatband  68  is attached to the lower peripheral edge  40  so that the forward sweatband mid point  84  coincides with the forward midpoint  48  and the aft sweatband midpoint  108  coincides with the aft midpoint  56 . 
     The attachment of the lower edge  74  of the sweatband  68  to the lower peripheral edge  40  possesses a flexibility which permits the sweatband loop to be in the stowed  124  or deployed  128  position when wearing the self-sizing baseball cap  10 . The stowed position  124  has the outer surface  120  of sweatband flush against the inner surface  34  of the crown portion  30 . The deployed position  128  has the outer surface  120  of the sweatband flush against the head of the wearer of the self-sizing baseball cap  10 . 
     In a variation of the invention, the first predetermined length comes in a short and a long length to accommodate a range of head sizes comfortably. The short length is sized to fit small to medium size heads comfortably. The long length is sized to fit large to extra large size heads comfortably. 
     In another variation of the invention, the sweatband  68  is created from two or more layers. Each layer is shaped as an elongated rectangle with an upper edge, a lower edge, a first edge, a second edge, an inner surface, an outer surface, and a first predetermined width. 
     The two or more layer sweatband has an inner layer  122  and an outer layer  124 . The outer surface of the inner layer  122  is attached to the inner surface of the outer layer  124 . 
     In yet another variation of the invention, each sweatband layer is made from different materials. 
     In still another variation of the invention, each sweatband layer is made from the same material. 
     In a different variation of the invention, the inner surface  106  of the inner layer  122  of the sweatband  68  is made from a material that feels comfortable to a wearer during long term contact with the wearer&#39;s skin or hair. 
     In another different variation of the invention, the outer surface  110  of the outer layer  126  of the sweatband  68  is made from a material that feels comfortable to a wearer during long term contact with the wearer&#39;s skin or hair. 
     In yet a different variation of the invention, each sweatband layer is either sweat absorbent or non-sweat absorbent. 
     In still a different variation of the invention, the inner layer  122  is uniaxially stretchable. 
     In still another different variation of the invention, the inner layer  122  is biaxially stretchable. 
     In distinctive variation of the invention, the outer layer  126  is uniaxially stretchable. 
     In another distinctive variation of the invention, the outer layer  126  is biaxially stretchable. 
     A second version of the invention, as shown in FIGS. 3 and 4, is a self-sizing baseball cap  210 . The self-sizing baseball cap  210  includes a plurality of fabric gores  214  of substantially triangular shape. Each fabric gore  214  has a first side  218 , a second side  222  and third side  226 . A crown portion  230  is created by attaching the first side  218  of the gore  214  to the second side  222  of another adjacent gore  214  and so forth until the creation of a closed section of essentially hemispherical shape. The crown portion  230  has an inner surface  234  and an outer surface  238  and a lower peripheral edge  240 . The lower peripheral edge  240  has a forward portion  244 , a forward midpoint  248 , an aft portion  252 , an aft midpoint  256  and a circumferential linear perimeter of a first predetermined length. 
     A visor  264  of an essentially rigid nature is attached to the forward portion  44  of the lower peripheral edge  240 . 
     A sweatband  268  is provided. The sweatband  268  is created from two or more sweatband segments  270 . Each sweatband segment  270  is shaped as an elongated rectangle with an upper edge, a lower edge  274 , a first edge  276 , and a second edge  280  and a first predetermined width  288 . 
     The first edge  276  of the sweatband segment  270  is attached to the second edge  284  of an adjacent sweatband segment  292  and so forth to create a closed loop, two or more piece the sweatband  268 . The sweatband  268  has an inner surface, an outer surface  320  and a circumferential linear extent of a first predetermined length. 
     The sweatband  268  is attached to the lower peripheral edge  240  so that the forward sweatband mid point  284  coincides with the forward midpoint  248  and the aft sweatband midpoint  308  coincides with the aft midpoint  256 . 
     The attachment of the lower edge  274  of the sweatband  268  to the lower peripheral edge  240  possesses a flexibility that permits the sweatband loop to be in the stowed  324  or deployed  328  position when wearing the self-sizing baseball cap  200 . The stowed position  324  has the outer surface  320  of sweatband flush against the inner surface  234  of the crown portion  230 . The deployed position  328  has the outer surface  320  of the sweatband flush against the head of the wearer of the self-sizing baseball cap  210 . 
     In a variation of the invention, the first predetermined length comes in a short and a long length to accommodate a range of head sizes comfortably. The short length is sized to fit small to medium size heads comfortably. The long length is sized to fit large to extra large size heads comfortably. 
     In yet another distinctive variation of the invention, each sweatband segment  270  is a different color or the same color as the other the sweatband segments. 
     In still another distinctive variation of the invention, the sweatband segment  270  is sweat absorbent. 
     In a discrete variation of the invention, a sweatband segment  270  is non-sweat absorbent. 
     In another discrete variation of the invention, a sweatband segment  270  is uniaxially stretchable. 
     In yet another discrete variation of the invention, a sweatband segment  270  is biaxially stretchable. 
     In a distinguishable variation of the invention, each sweatband segment  270  is made from different materials. 
     In another distinguishable variation of the invention, each sweatband segment  270  is made from the same material. 
     In yet another distinguishable variation of the invention, each sweatband segment  270  is created from two or more layers. Each sweatband segment layer is shaped as an elongated rectangle with an upper edge, a lower edge, a first edge, a second edge, an inner surface, an outer surface, and a first predetermined width. 
     The two or more layer sweatband segment has an inner layer  322  and an outer layer  324 . The outer surface of the inner layer  322  is attached to the inner surface of the outer layer  324 . 
     In still another distinguishable variation of the invention, each sweatband segment layer is made from a different material than another sweatband segment layer. 
     In a discernable variation of the invention, each sweatband segment layer is made from the same material. 
     In another discernable variation of the invention, the inner surface  294  of the inner layer  322  of the sweatband segment layer  270  is made from a material that feels comfortable to a wearer during long term contact with the wearer&#39;s skin or hair. 
     In yet another discernable variation of the invention, the outer surface  310  of the outer layer  326  of the sweatband segment layer  270  is made from a material that feels comfortable to a wearer during long term contact with the wearer&#39;s skin or hair. 
     In still another discernable variation of the invention, each sweatband segment layer is sweat absorbent or non-sweat absorbent. 
     In a hitherto discernable variation of the invention, the inner layer of each sweatband segment  270  is uniaxially stretchable. 
     In another hitherto discernable variation of the invention, the inner layer of each sweatband segment  270  is biaxially stretchable. 
     In yet another apparent variation of the invention, the outer layer of each sweatband segment  270  is uniaxially stretchable. 
     In still another apparent variation of the invention, the outer layer of each sweatband segment  270  is biaxially stretchable. 
     In another hitherto apparent variation of the invention, each sweatband segment layer is a different color or the same color as the other the sweatband segment layers.