Abstract:
Headwear systems are provided which include hats such as sports caps and the like having one or more detachable liners that enhance comfort and aesthetic appeal. The liners are interchangeable, one with another. The liners include a resilient, non-absorbent core layer made of separate bands different materials that are effective to retain the shape and form of the hat. The liners include a zipper mechanism for enabling removable attachment of the liners to the hat.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     The present invention is generally directed to headwear and is more specifically directed to hats, for example, caps, including removable liners.  
         [0002]     Hats or caps are commonly provided with a liner, for example, a moisture absorbent material that lines at least a portion of the inner surface of the hat or cap, usually at the forehead region. Typically, such liners are permanently sewn into the cap and are designed to absorb perspiration and/or provide a soft surface for contact with the facial skin of the wearer or to protect the main fabric of the hat from becoming soiled with perspiration and dirt.  
         [0003]     Other hats or caps are unlined, and essentially comprise of a single layer of cloth, for example, canvas material. In these caps, the surface of the cap which contacts the skin of the wearer is simply the underside of the generally rough canvas material of which the cap is made.  
         [0004]     In either case, each time the hat or cap is worn, the liner or inner surface of the cap material continues to accumulate dirt and perspiration. Naturally, unless the cap is thoroughly washed or cleaned, the cap will eventually become stained, malodorous, and/or generally unattractive from the accumulated grime and perspiration.  
         [0005]     Washing a hat or cap is not ideal and the hat or cap may lose its shape and structural integrity. Soaking a cloth cap, for example, in soapy water, tends to alter the fit and even the appearance thereof.  
         [0006]     It is commonly accepted that the only solution to is to discard an old worn cap and replace with a new one. It is not uncommon for some wearers to be very reluctant to discard a hat which may have been costly, or to which the wearer has developed a sentimental attachment. Caps which may have special sentimental significance to a wearer may be difficult or impossible to be satisfactorily replaced.  
         [0007]     Many removable hat liners have been proposed. Conventional removable hat liners are generally directed to sweatband-style liners that are directed at addressing problems caused by accumulating perspiration.  
         [0008]     Hahn, et al., U.S. Pat. No. 6,738,985 discloses a disposable sweatband liner for a hat or cap, the liner being attached to the hat or cap by an adhesive strip.  
         [0009]     Young, U.S. Pat. No. 5,613,248 teaches a removable sweatband for a hat using snap fasteners.  
         [0010]     Moore, U.S. Pat. No. 5,553,326 discloses a removable, washable sweatband for a hat. The sweatband is attached to a hat using a “zip-lock” type closing means, such as the type used in plastic bags.  
         [0011]     Nunnery et al., U.S. Pat. No. 4,468,817 discloses a washable, terry-cloth strip that is connectable to a safety helmet using snap fasteners.  
         [0012]     None of the conventional hat liner devices are directed at providing a significant increase in comfort to a wearer or to improving the appearance of a cap. The present invention meets all the needs that are addressed by the prior art and meets other needs as well.  
         [0013]     It would be advantageous to provide new hat assemblies, for example, hat assemblies that include removable liners that are more robust, more attractive and provide greater options than those proposed in the prior art.  
       SUMMARY OF THE INVENTION  
       [0014]     Accordingly, new headwear systems are provided. The headwear systems of the present invention provide hats or caps that are exceptionally comfortable, versatile and visually appealing. Further, the headwear systems provide effective means for retaining the form and shape of a hat or cap, thereby extending the useful life thereof.  
         [0015]     The systems generally comprise a headwear article, such as a fabric cap, for example a sports cap, a hat, or a visor. For purposes of simplicity, the term “cap” is often used herein rather than the term “headwear article”. It should be appreciated however that the terms headwear article and cap, as used herein and unless expressly stated otherwise, are intended to include most any type of sports cap, visor, functional headwear, for example, that worn by golfers, beachgoers, surfers, hikers and the like, knit cap, sunhat, straw hat, lifeguard hat, and any other type of headwear that would be useful in systems of the present invention.  
         [0016]     The headwear article generally includes a peripheral edge, a crown portion which generally extends around a portion of the interior surface of the headwear article and faces the forehead of a wearer. When the headwear article is worn, the crown portion extends about from ear to ear of a wearer. The headwear article may further include a visor portion extending outwardly away from the crown portion. The headwear article may be made of canvas, denim or other medium or heavy gauge fabric material, for example, a material commonly used to make conventional caps.  
         [0017]     The system further comprises at least one liner member that is removably attachable to the crown portion of the headwear article. The liner member has a suitable length for covering at least a portion of the crown portion. The length of the liner member, for example, is about equivalent to the length of the crown portion. The liner member is structured to be removably attached to the crown portion.  
         [0018]     Advantageously, the liner member is structured to provide support to the crown portion and maintain a form and shape thereof. In addition, the liner member is structured to provide a smooth, close fit between the crown portion and the liner member. Preferably, the liner member will not buckle or protrude when attached to the crown portion.  
         [0019]     For example, in a preferred embodiment, the liner member generally includes a core layer, for example, a resilient core layer, and an outer layer, for example an absorbent, fabric outer layer covering or enclosing at least a major surface of the core layer. The liner member further includes an attachment mechanism for enabling manual, removable attachment of the liner member to the crown portion.  
         [0020]     The core layer may comprise a first band and a second band which are aligned in a generally side by side relationship along the length of the liner member. In a particularly useful embodiment, the first band has a greater stiffness than the second band. In some embodiments, the first band is relatively narrower in width than the second band. The core layer may be made of separate bands of different materials. The bands of the core layer are structured to retain the shape and form of the hat such that the hat will stay “new-looking” even after long term wear.  
         [0021]     The system is structured such that when the liner member is attached to the headwear article, the generally more supportive first band has an edge that aligns with the peripheral edge of the headwear article. The second band, preferably made of a softer or more flexible material, extends upward and away from the first band. The second band is preferably spaced apart form the peripheral edge by a distance sufficient provide a smooth front appearance to the headwear when worn. For example, the second band extends away from the first band a distance of about 1.0 inch or more. Further, the liner member may include a flexural region located generally along at least a major portion of the length of the liner member. More specifically, the flexural region may provide a hinge formed in the liner member generally between the first band and the second band  
         [0022]     The core layer may be made of suitable materials that provided strength and a desired balance of flexibility, resiliency and rigidity to the liner member. In some embodiments, the core layer may be made of non-woven materials, for example, molded polymeric materials. The core layer may be generally non-absorbent, for example, relative to the outer layer.  
         [0023]     The outer layer may comprise a soft, comfortable, absorbent fabric material, for example, velour, terrycloth, or other suitable fabric material. Preferably, the absorbent layer substantially entirely encloses the core layer. For example, the outer layer encloses the core layer in a manner such that none of the core layer, or at least no significant region of the core layer, is exposed on an exterior of the liner member.  
         [0024]     The system further comprises an attachment mechanism for removably attaching the at least one liner member to the crown portion. For example, the attachment mechanism may comprise a zipper mechanism extending the length of the liner member. One toothed strip of the zipper mechanism may be permanently attached to the crown portion and another toothed strip of the zipper mechanism may be permanently attached to the liner member.  
         [0025]     In some embodiments, the systems comprise a plurality of interchangeable liner members for enhancing versatility of the system. The liner members may be made of different materials and/or different colors.  
         [0026]     In other embodiments, headwear shape-retaining systems are provided which generally comprise a liner member having the aspects described elsewhere herein and including means for enabling removable attachment of the liner member to a cap.  
         [0027]     In a specific embodiment of the invention, headwear systems are provided which comprise a conventional headwear article or cap that is provided as a primary component of the system. The system further comprises an assortment of liner members that are provided, for example, in the form of a display near the cap and available for sale therewith. One or more of the liner members can be selected by the consumer to be purchased with the cap. The assortment of liner members may be provided in various colors, patterns and materials to enable selection of a combination of a cap and a liner member that the wearer prefers.  
         [0028]     Any and all features described herein and combinations of such features are included within the scope of the present invention provided that the features of any such combination are not mutually inconsistent.  
         [0029]     These and other features, aspects and advantages of the present invention will become apparent hereinafter, particularly when considered in conjunction with the following claims, detailed description and drawings in which like parts bear like reference numerals. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0030]      FIG. 1  is a perspective top view of a system in accordance with the present invention comprising an article of headwear.  
         [0031]      FIG. 2  is a perspective bottom view of the system shown in  FIG. 1  showing a liner member removably connected to the article of headwear.  
         [0032]      FIG. 3  is a perspective bottom view of the system with the liner member as it is being attached to a crown portion of the article of headwear shown in  FIGS. 1 and 2 .  
         [0033]      FIG. 4  is a perspective bottom view of the system shown in  FIGS. 1 and 2  with the liner member removed therefrom.  
         [0034]      FIG. 5  is a partial cut-away plan view of the liner member.  
         [0035]      FIG. 6  is a cross-sectional view of the liner member.  
         [0036]      FIG. 7  is a perspective view of a plurality of different liner members for use in the systems of the invention.  
         [0037]      FIG. 8  is an alternative embodiment of the invention comprising an article of headwear, a liner member, and shape-retaining members. 
     
    
     DETAILED DESCRIPTION  
       [0038]     Turning now to  FIGS. 1 and 2 , a headwear system  10  in accordance with the invention is shown. The headwear system  10  generally comprises an article of headwear, in this example, a canvas cap  12 , and at least one liner member  14  that is removably attached to a crown portion  16  of the cap  12 . The crown portion  16 , as used herein, is generally intended to refer to a region disposed along front and side portions of the cap  12  and which extends about from ear to ear of a person wearing the cap  12  on his or her head. The crown portion  16  includes an inner surface portion of the cap  12  which faces the forehead of the person. In this specific embodiment shown, the cap  12  includes a visor portion  18  extending outwardly away from the crown portion  16 . As shown, the liner member  14  has a longitudinal edge that aligns with a peripheral edge  20  of the cap  12 .  
         [0039]     Certain aspects of the present invention may be more clearly understood with specific reference to  FIGS. 3-5 , which show, respectively, the system  10  with the liner member  14  during attachment to the cap  16 , the cap  12  having the liner member  16  removed therefrom, and the liner member  14  in cut-away view.  
         [0040]     The liner member  14  preferably has a suitable length for covering at least a portion of the cap crown portion  16 . The system  10  further comprises a suitable attachment mechanism for facilitating removable attachment of the liner member  14  to the cap  12 . The attachment mechanism provides a means for enabling manual removal of the liner member  14 , for example, when the liner mechanism  14  has become worn, soiled or stained, and further, is designed to enable exchange of the liner member  14  for another liner member (not shown) using the same mechanism.  
         [0041]     Preferably, the attachment mechanism comprises a zipper mechanism  22 . The zipper mechanism  22  may be a conventional zipper mechanism. The zipper mechanism preferably includes a first toothed strip  22   a  with a pull tab  26  and a cooperative second toothed strip  22   b.  The first toothed strip  22   a  with pull tab  26  is preferably secured directly and permanently to a rim  28  of the crown portion  16  as shown in  FIG. 3  and  4 . The second toothed strip  22   b  is preferably secured substantially entirely across and permanently to the liner member  14 , for example, on a face of the liner member  14  such as shown in  FIGS. 3 and 5 . Securement of the toothed strips  22   a  and  22   b  to the cap  12  and liner member  14  respectively, may be accomplished in any suitable manner, for example, by sewing, adhesives and the like and combinations thereof. Advantageously, the provision of the zipper mechanism in the present systems ensures that the liner member  14  will be consistently attached to the cap  12  in the intended, correct position.  
         [0042]     Other attachment mechanisms are also contemplated and are considered to be within the scope of the invention. For example, the attachment mechanism may alternatively comprise hook and loop fastener strips, snaps, buttons, or the like. Any attachment mechanism useful in the present invention is preferably one that is structured to enable manual removable attachment of the liner member to the cap in a non-complicated fashion by an ordinary adult human being.  
         [0043]     Referring back briefly to  FIG. 2 , the system  10  is designed and structured such that liner member  14 , when properly attached to the cap  16  by means of zipper mechanism (not shown in  FIG. 2 ), will cover or conceal all components of the zipper mechanism. This enhances visual appeal of the liner member  14  in cap  12 . An outer surface  28  of the liner member  14 , which faces the forehead of the wearer, provides a soft, cushiony, visually appealing surface, for example, when the system  10  is not being worn.  
         [0044]     The liner member  14  is sized and shaped to cover at least the wearer&#39;s forehead. In the shown embodiment, the liner member  14  has a length L preferably less than a total circumferential length of the cap  12 . For example, the length L may be about equivalent to the length of the crown portion  16 . For use with a standard sized adult cap, the length of the liner member  14  is preferably between about 15 inches and about 20 inches, more preferably between about 16 inches and about 19 inches. A width W of the liner member is preferably between about 1.0 inch and about 2.0 inches. In a specific embodiment, the length L of the liner member  14  is about 18.75 inches and the width W is about 1.5 inches. The liner member  14  has a sufficient flexibility in the direction of length L to flex and curve from a flat configuration to a curve matching that of the inner surface of the cap  12 . Advantageously, the liner member has a structure, for example, a sufficient stiffness or rigidity in the direction of width W, to provide support to and maintain the shape of at least the crown portion  16  of the cap  12 .  
         [0045]     Turning now to  FIGS. 5 and 6 , the liner member  14  may include a flexible longitudinally extending region, herein referred to as “flexural region”  30 , for example, a hinged region. The flexural region  30  extends along length L, for example at least a major portion of length L of the liner member  14 . Preferably, the flexural region  30  extends along the entire length of the liner member  14 . More specifically, the flexural region  30  is a region of substantially greater flexibility in the direction of width W, for example, relative to any other longitudinally extending region of the liner member  14 .  
         [0046]     For example, in the shown embodiment, the liner member  14  comprises a core layer  38 , for example, a substantially non-absorbent, resilient core layer, and an outer layer  40 , for example an absorbent, relatively flexible, soft outer layer. Preferably, the outer layer  40  substantially entirely encloses the core layer  38 , such as shown in  FIG. 6 .  
         [0047]     The core layer  38  preferably includes a first band  44  made of a first material having a first stiffness and a second band  46  made of a second stiffness that is less than the first stiffness. The first band  44  may have a smaller width than a width of the second band  46 . The first band may have a width of about 0.5 inch. The first band  44  includes a longitudinal edge  44   a  which generally aligns with the peripheral edge  20  of the cap  12  when the liner member  14  is properly attached thereto. In a specific embodiment, the first band  44  comprises 12 mm (about 0.5 inch) polyester Rigilene boning material, for example, and the second band  46  comprises a belting material having a width of about 24 mm (about 1.0 inch) or greater and available under the tradename Dritz® Belting. Other suitable materials are also contemplated and are considered to be within the scope of the invention.  
         [0048]     The first band  44  and the second band  46  are aligned side by side as shown, and may be connected by stitching  52 , for example, cross stitching such as shown in  FIG. 5 . The flexural region  30  may be formed by an interface region located generally between the first band  44  and second band  46 .  
         [0049]     Turning now briefly to  FIG. 7 , in some embodiments of the invention, a plurality of liner members  14  are provided, for example an assortment of liner members that are different colors and/or different materials. For example, liner  14   a  comprises outer layer which is a thick velour material so as to provide warmth to the wearer during cool temperatures. On the other hand, liner member  14   b  may comprise outer layer  40   b  which is a light, highly absorbent terrycloth material  40   b,  such liner member  14   b  being selected for wear, for example, during warm weather and/or when excessive perspiration is expected.  
         [0050]      FIG. 8  shows another system  110  of the invention which is similar to system  10 , the difference being that system  110  further comprises one or more shape-retaining members  64 . Shape retaining members  64  extend generally away from liner member  114  and are structured to provide more substantial shape retaining function to the cap  116 . Preferably, the shape-retaining members  64  are made of a smooth, flexible plastic material having sufficient thickness to maintain the form of the cap  112  without causing substantial discomfort to the wearer.  
         [0051]     Although there has been hereinabove described one or more exemplary embodiments of a boat propeller safety cover, in accordance with the present invention, for purposes of illustrating the manner in which the present invention may be used to advantage, it will be appreciated that the present invention is not limited thereto. Accordingly, any and all modifications, variations and/or equivalent arrangements which may occur to those skilled in the art should be considered to be within the scope of the present invention as defined in the appended claims.