Headwear with size adjustment feature

A headwear article having an inverted cup-shaped crown for placement over the head of an individual, a band on the crown with a surface embracing the head of the individual wearing the headwear and an inflatable element on at least one of the crown and band for varying the effective diameter of the band surface.

BACKGROUND OF THE INVENTION 
1. Field of the Invention 
This invention relates to headwear and, more particularly, to a headwear 
article that can be configured to accommodate a plurality of different 
head sizes. 
2. Background Art 
Human head sizes vary considerably. To accommodate all users, it has 
heretofore been necessary for purveyors of headwear to carry a wide range 
of sizes. 
It is known to incorporate an adjustable feature into headwear so as to 
limit the number of different sizes that must be stocked. Several 
different ways of affording this adjustment are known. For example, it is 
known to provide an elastic band within the crown of the hat. This 
accommodates a limited range of sizes. 
One problem with the use of an elastic band is that, when the crown is 
pliable, the elastic tends to collapse the crown and distort the 
configuration of the crown. Further, the elastic embraces a smaller head 
with a lesser force than it would a larger head. 
Another prior art adjusting structure consists of two connectable strap 
ends carried by the lower edge of the crown. The ends may be selectively 
connected as through a belt-type connection or through a releasable pin 
and aperture arrangement to selectively reduce and enlarge the crown 
opening. The straps normally deform the crown configuration, particularly 
when the straps are connected so as to accommodate a small head size. 
Further, the adjustment can take place only in fixed increments. The 
user's head size may be such that one size may be too small and the next 
available size may be too large to comfortably accommodate the head. 
Another known prior art structure employs an adjustable drawstring carried 
in a receptive sleeve within the crown. The user draws the string to 
produce a desired diameter and then ties the ends thereof to fix that 
diameter. This requires that the user take the headwear off, tie the 
drawstring ends and replace the headwear. There is no frame of reference 
that allows the user to make fine adjustments, either to a larger or 
smaller size. Consequently, it becomes a trial and error exercise, which 
is clearly inconvenient. 
A further problem with the prior art structures, particularly those with 
fixed diameters at the bottom of the crown, is that the crown is 
relatively inflexible and the size of the opening at the bottom thereof is 
fixed. It is difficult to get a perfect head fit and consequently the user 
generally settles for a fit that is either too loose or too tight. 
SUMMARY OF THE INVENTION 
The present invention is specifically directed to overcoming the 
above-enumerated problems in a novel and simple manner. 
It is the principal objective of the present invention to afford a headwear 
article that can accommodate a wide range of head sizes without altering 
the appearance of the headwear and which adjustment can be simply and 
conveniently carried out by the user. It is a further objective of the 
invention to afford a headwear piece that consistently and comfortably 
embraces the head of the user regardless of the head size. 
More particularly, applicant's invention is a headwear article having an 
inverted cup-shaped crown for placement over the head of an individual, a 
band on the crown with a surface embracing the head of the individual 
wearing the headwear and an inflatable element on at least one of the 
crown and band for varying the effective diameter of the band surface. 
The band has a first effective diameter. By inflating the element, the 
effective band diameter is varied. 
The inflatable element can take any of a variety of different 
configurations. There can be individually spaced pads or a ring-shaped 
bladder, extending through at least 180.degree., and preferably through 
360.degree.. 
Preferably, the bladder resides between a sweat band and an inside surface 
of the crown. Inflation of the bladder shifts the sweatband inwardly 
towards the center of the crown to reduce the effective diameter of the 
band. Alternatively, the sweatband consists of a plurality of layers and 
the bladder is captured operatively between the sweatband layers. 
With the inventive structure, the head of the user is comfortably embraced 
by the band. The amount of inflation of the bladder can be controlled to 
produce a desired force on the user's head. At the same time, the bladder 
has inherent resiliency which adds to the user's comfort. 
The bladder has an associated valve which allows for inflation and 
deflation thereof. A simple hand-held air pump, as commonly used to 
inflate/deflate footballs, basketballs, etc., can be employed to fill the 
bladder. 
Alternatively, to facilitate inflation of the bladder, a pump can be 
integrally attached to the headwear article. In a preferred form, the pump 
can be formed as a cup-shaped/semispherical membrane disposed over a 
one-way valve opening. By collapsing the membrane, air or other fluid is 
forced into the bladder to effect inflation thereof. The membrane can be 
made to have a sufficiently low profile so as not to detract from the 
appearance of the headwear piece. The user can effect inflation with the 
headwear in place. This allows a desired pressure to be developed on the 
user's head by the band--that is, the user can feel the proper adjustment. 
The inventive structure has utility in many different headwear industries. 
For example, it is particularly adaptable to baseball-style caps, but can 
be used in virtually all headwear having a crown which fits over the head 
of a user. The inventive structure is ideal when used in association with 
a flexible crown. The effective diameter of the crown is changed from the 
inside of the crown so that the external appearance of the flexible crown 
is unaffected by the diameter adjustment. 
When the bladder is used in conjunction with a flexible crown, an 
additional dimension is added to the headwear. The outer surface of the 
crown can reconfigure with the bladder to conform to different size and 
shape wearer heads. As the wearer directs the crown over his or her head, 
the bladder and outer crown surface readily conform. 
The bladder may be made from any of a variety of different materials. A 
preferred material is latex, however silicone rubber or vinyl can be used 
as well. In one form of the invention, the bladder is formed by strips of 
rubber material having a width on the order of 3/4 of an inch and a length 
on the order of 24 inches. Two strips are placed face-to-face and the 
opposite joining edges are bonded, as by sonic welding or the use of an 
adhesive. 
The bladder can be sewn directly to one or both of the sweat band and 
crown. 
A conventional style cap can be retrofit with the inventive structure with 
minimal expense. The incorporation of the bladder can be accomplished 
quite simply.

DETAILED DESCRIPTION OF THE DRAWINGS 
An exemplary piece of headwear is shown at 10 suitable for incorporation of 
the present invention. The headwear 10 depicted is a baseball-style cap, 
however, it should be recognized that the invention is useable in 
virtually all different styles of headwear having a continuous annular 
edge which embraces a user's head. 
The cap 10, as shown in FIGS. 1, 2 and 4, consists of an inverted, 
cup-shaped crown 12 to which a bill/visor 14 is affixed to project 
forwardly therefrom. The crown 12 is defined by six fabric gores 16 sewn 
together along adjacent abutting edges. The lower edge 17 of the crown 12 
defines an opening 18 to accommodate the user's head. 
A continuous, annular sweatband 20 is sewn onto the inside surface 22 of 
the crown 12 adjacent the lower crown edge 17. The sweatband 20 is made 
from a moisture absorbent material to absorb perspiration from the user 
and shield the fabric crown 12 from the user's head to prevent 
perspiration stains as might discolor or otherwise detract from the 
appearance of the cap 10. An optional plastic layer (not shown) is 
interposed between the sweatband 20 and crown 12 to prevent migration of 
moisture from the sweatband 20 to the crown 12. 
In a conventional baseball cap, the effective diameter of the crown 12 at 
the sweatband 20 determines the cap size. The diameter is characterized as 
the "effective" diameter because neither the crown opening 18 nor the 
human head is perfectly round. It is known to incorporate belt-type 
structures and/or elastic into a crown so as to selectively enlarge and 
diminish the effective diameter of the crown opening 18. The present 
invention is concerned with an alternative structure for effecting size 
adjustment of the crown opening 18. 
In FIGS. 2 and 3, the effective diameter of the crown opening 18 is 
identified as dimension D1. The invention contemplates the provision of a 
flexible bladder 26 inside of the crown 12. In the embodiment of FIGS. 1, 
2 and 4, the sweatband 20 consists of two fabric layers 27, 28. The 
bladder 26 is sandwiched between the facing surfaces 29, 30 on the layers 
27, 28, respectively. Separate lines of stitching 32, 34, respectively on 
the top and bottom of the sweatband 20, secure the sweatband layers 27, 28 
together and thereby captively maintain the bladder in the operative 
position of FIGS. 1 and 4. The lower line of stitching 34 extends into the 
crown 12 so that the sweatband 20 can be folded about the stitching line 
34 selectively up into the space 35 bounded by the crown 12 against the 
crown surface 22 and away therefrom. 
The bladder 26 is preferably made from a flexible material such as rubber, 
and preferably latex rubber. It could be made from other materials such as 
vinyl or any structure that is impermeable to air and readily expandable. 
The bladder 26 in FIGS. 1, 2 and 4 is formed as a single piece. 
An inflation device/pump is integrated into the cap 10 at 36. The pump 36 
consists of a semi-spherical diaphragm 38 which is collapsible to force a 
charge of air through a one-way valve 40 into the space 42 bounded by the 
bladder 26. Inflation of the bladder 26 causes the peripheral inside 
sweatband surface 44 to be collapsed towards the center of the crown 
opening 18, thereby resulting in a reduced effective diameter for the 
opening 18, designated D2 in FIG. 3. 
The present invention contemplates numerous configurations for the pump 36 
and one-way valve 40 in FIGS. 1, 2 and 4. The one-way valve 40 consists of 
two cooperating flexible flaps 46, 48, which are pressed into sealing 
engagement with each other by the fluid pressure internally of the bladder 
26. By depressing the pump diaphragm 38, the flaps 46, 48 are forced apart 
by the incoming air pressure to admit air into the bladder space 42 to 
thereby effect expansion thereof. A bleeder port 49 allows the diaphragm 
38 to spring back after it is depressed. 
The invention contemplates other variations of the structure shown in FIGS. 
1, 2 and 4. In FIGS. 3 and 5, a modified bladder configuration is shown. 
In FIG. 3, individual bladder segments 50, 52, 54, 56 are captured 
directly between the outer sweatband layer 27 and inside surface 22 of the 
crown 12. Each of the bladder segments 50, 52, 54, 56 extends through 
slightly less than 90.degree. so that all four sections 50, 52, 54, 56, 
which are equidistantly spaced, cooperatively extend through approximately 
360.degree. . Communication between adjacent sections 50, 52, 54, 56 is 
effected through conduits 58, which may be simple tubes. The invention 
contemplates the use of one or more of the segments 50, 52, 54, 56. For 
example, it is possible to incorporate only one segment 50, 52, 54, 56 or 
to incorporate only two of the diametrically opposed bladder segments 50, 
52, 54, 56. Inflation of two opposite segments causes reduction of the 
effective diameter of the opening 18 and a relatively balanced force 
embracing the user's head. 
The embodiment in FIG. 3 also employs an external hand-operated pump 62. A 
one-way valve 64, of the type conventionally used to inflate/deflate 
sports balls, such as footballs, basketballs, beach balls, etc. is 
incorporated into the bladder 26 at the rear of the cap 10. The valve 64 
has a fitting 66 to releasably connect to a cooperating fitting 68 on the 
pump 62. The hand operated pump 62 is also of conventional construction. A 
pressurized supply of air could also be used to inflate the bladder 
sections 50, 52, 54, 56. 
A further modification of the cap 10 is shown in FIG. 6. In FIG. 6 a 
cut-out 72 is provided at the rear of the cap 10. An elastic band 74 spans 
the distance between the free edges 76, 78 at the bottom of the crown 12 
and resiliently draws the edges 76, 78 towards each other to diminish the 
width of the cut-out 72. This arrangement can be used in conjunction with 
bladder segments 80, 82, similar to those 50, 52, 54, 56, incorporated 
into the crown 12, as previously described. 
A further variation in the structure in FIGS. 3 and 5 involves the bladder 
26. The bladder 26 is formed by two flat sheets 84, 86 on the order of 
3/4" in width and 24" in length. The opposite edges 89, 90 of the sheets 
84, 86 are sonically welded, bonded with an adhesive, or otherwise joined 
to define a leakproof chamber 92. Separate lines of stitching 94, 96 
respectively secure the sweatband layer 20 to the bladder 26 and the 
bottom bladder edge 90 to the crown 12. The top edge 89 of the bladder 26 
could be secured to the crown 12, though it preferably is not so as to 
allow the sweatband layer 20 to fold away from the crown surface 22 as the 
bladder 26 is inflated. 
With the inventive structure, it is possible for the user to place the cap 
10 on his or her head. The integral pump 38 can then be operated with the 
cap 10 in place to adjust the diameter of the cap opening 18 to 
comfortably fit the user's head. The bladder 26, in addition to allowing 
variation in the diameter of the cap opening 18, provides a cushioned fit 
around the head of the user adding considerably to the comfort of the 
user. The elastic band 74 in FIG. 6 also exerts a slight bias around the 
head of the user to maintain the cap 10 in place on the user's head. 
The flexible nature of the crown allows it to reconfigure with the bladder 
26 to conform in a radial direction to different size and shape wearer 
heads. The headwear piece readily automatically conforms as the crown is 
pressed over the wearer's head. 
It can be seen that the inventive structure can be simply and economically 
incorporated into a conventional-style cap. It can also be retrofit into 
conventional caps. 
The foregoing disclosure of specific embodiments is intended to be 
illustrative of the broad concepts comprehended by the invention.