Headwear with stretchable sweatband

An article of headwear having an adjustable configuration includes a crown portion and a sweatband secured to a peripheral edge of the crown. The sweatband includes an inner piece of stretchable fabric material folded about itself such that opposing longitudinal edges of the inner piece are proximate one another to form a seam, and a binding of elastic material secured to the inner piece such that it covers the seam. The inner piece may be wrapped about a filler piece of stretchable fabric.

FIELD OF THE INVENTION

This invention relates generally to headwear, and, in particular, to headwear having a stretchable sweatband to adapt to various head sizes.

BACKGROUND OF THE INVENTION

Headwear can come in many forms including hats, caps, bucket style, visors, etc. Such headwear, including baseball caps, for example, may be classified as either fitted or adjustable. Fitted headwear is generally manufactured in a wide range of sizes, with each size having a fixed circumference to accommodate an individual with a corresponding head circumference. Adjustable headwear may incorporate an adjustment system that permits a single article of headwear to accommodate individuals with various head dimensions. Accordingly, a manufacturer can produce a line of adjustable headwear with significantly fewer sizes than a corresponding line of fitted headwear, since each adjustable headwear article can accommodate a range of sizes rather than a particular size. Although adjustable headwear is generally more complex to manufacture than fitted headwear, the manufacturing efficiency of producing relatively few sizes reduces the overall cost of adjustable headwear in comparison with fitted headwear. In addition, a retailer can carry a line with fewer articles of headwear, thereby realizing reduced handling and inventory costs.

A baseball cap having a conventional style of adjustment system is disclosed in U.S. Pat. No. 5,272,772 to Hahn. A rear portion of the baseball cap includes a cutout area and two overlapping straps that extend into the cutout area. One of the straps includes a plurality of protrusions and the other strap includes a plurality of corresponding apertures. By snapping the protrusions into different apertures, the circumference of the baseball cap can be adjusted. A similar adjustment system is disclosed in U.S. Pat. No. 4,815,148 to Satterfield, and incorporates portions of a hook and loop fastener that are located on opposite sides of a slit formed in the baseball cap.

A drawback to the baseball caps of Hahn and Satterfield relates to the aesthetic appearance of the adjustment system. The material forming the crown of fitted baseball caps extends entirely around the head. In contrast, the material forming the crown of the baseball caps of Hahn and Satterfield includes the cutout area and slit, respectively, which breaks the continuity of the crown. Accordingly, manufacturers often incorporate an adjustment system into baseball caps that provides the appearance of a fitted baseball cap. For example, U.S. Pat. No. 6,122,774 to Park; U.S. Pat. No. 5,715,540 to Cho; and U.S. Pat. No. 5,615,415 to Beckerman each disclose adjustable baseball caps that incorporate a stretchable material. U.S. Pat. No. 5,031,246 to Kronenberger discloses an adjustable baseball cap that incorporates an inflatable bladder located within material that forms the bottom of the crown to vary the effective diameter of a headband in the crown.

Problems associated with many prior art adjustable headwear include complex construction and excessively bulky sweatbands. It is an object of the present invention to provide an article of headwear that reduces or wholly overcomes some or all of the difficulties inherent in prior known devices. Particular objects and advantages of the invention will be apparent to those skilled in the art, that is, those who are knowledgeable or experienced in this field of technology, in view of the following disclosure of the invention and detailed description of certain preferred embodiments.

SUMMARY

The present invention is directed to an article of headwear that has an adjustable configuration to accommodate a range of head sizes, thereby reducing the number of articles of headwear required to fit various individuals as compared to the number of fixed size articles of headwear required to fit those same individuals.

In accordance with a first aspect, an article of headwear having an adjustable configuration includes a crown portion and a sweatband secured to a peripheral edge of the crown. The sweatband includes an inner piece formed of stretchable fabric material folded about itself such that opposing longitudinal edges of the inner piece are proximate one another to form a seam. A binding of elastic material is secured to a side of the inner piece having the seam.

In accordance with another aspect, an article of headwear having an adjustable configuration includes a plurality of gores forming a crown and a sweatband secured to a peripheral edge of the crown. The sweatband includes a filler piece of elastic material and an inner piece of stretchable fabric material folded about the filler piece of elastic material such that opposed longitudinal edges of the inner piece are proximate one another to form a seam. A binding of elastic material is secured to a side of the inner piece having the seam.

In accordance with a further aspect, an article of headwear having an adjustable configuration includes a crown formed of a plurality of gores. The gores are formed of a stretchable material. A bill is secured to the crown. A sweatband is secured to a peripheral edge of the crown. The sweatband includes a filler piece of elastic material and an inner piece of stretchable fabric material folded about the filler piece such that opposed longitudinal edges of the inner piece abut one another to form a seam. A binding of elastic material is sewn to a side of the inner piece having the seam.

Substantial advantage is achieved by providing an article of headwear with a stretchable headband. In particular, an adjustable article of headwear that can accommodate multiple head sizes can be produced with a simple construction and minimal bulk. These and additional features and advantages of the invention disclosed here will be further understood from the following detailed disclosure of certain preferred embodiments.

The figures referred to above are not drawn necessarily to scale and should be understood to present a representation of the invention, illustrative of the principles involved. Some features of the article of headwear depicted in the drawings have been enlarged or distorted relative to others to facilitate explanation and understanding. The same reference numbers are used in the drawings for similar or identical components and features shown in various alternative embodiments. Articles of headwear with a stretchable headband as disclosed herein will have configurations and components determined, in part, by the intended application and environment in which they are used.

DETAILED DESCRIPTION OF CERTAIN PREFERRED EMBODIMENTS

The following discussion and accompanying figures disclose an article of headwear having a stretchable configuration in accordance with the present invention. In the embodiments discussed herein, the article of headwear is disclosed as having the structure of a baseball cap and may be referred to herein as a hat. The concepts and features disclosed in the following discussion may, however, be applied to a wide range of headwear to impart a stretchable configuration that accommodates the head circumference of different individuals. Accordingly, the present invention is not limited to any particular type of headwear, but may be applied to a wide range of headwear, including, e.g., hats, caps, bucket style, and visors.

The present invention may be embodied in various forms. A preferred embodiment of an article of headwear or hat10is depicted inFIGS. 1–2and includes two principal elements; a crown portion20and a visor or bill portion30. Crown portion20forms a generally hemispherical covering for a head of an individual, and bill portion30extends outward in a generally horizontal direction from crown portion20to shade the face and eyes of an individual. The materials forming crown portion20extend entirely around a circumference of the wearer's head to provide hat10with the appearance of a fitted baseball cap that accommodates an individual with a specific head circumference. Hat10, however, incorporates an adjustment system that provides a stretchable configuration to accommodate the head circumferences of different individuals, as will be described in greater detail below.

Crown portion20includes a plurality of panels, commonly referred to as gores,21a–21fthat are attached together along abutting sides thereof. More specifically, crown portion20includes two front gores21aand21bthat are located adjacent to bill portion30, two side gores21cand21dthat are located on a left side and a right side of hat10, respectively, and two rear gores21eand21fthat are located in a rear area of hat10. The various gores21a–21fdefine an exterior surface22and an opposite interior surface23of crown portion20.

In a preferred embodiment, gores21a–21fare formed of a stretchable material that will deform in the presence of a tensile force to accommodate the head circumferences of different individuals. The material forming gores21a–21fmay be any generally planar material with the ability to substantially return to an original size and shape following tensile deformation. After being stretched to a reasonable degree, therefore, the material forming gores21a–21fis capable of substantially returning to an unstretched configuration. In other preferred embodiments, gores21a–21fare formed of a non-stretchable material.

Various materials are suitable for gores21a–21f, including polymer, synthetic textile, and natural textile materials, including, e.g., polyesters, cottons, woven and non-woven materials. In order to enhance the stretch properties of gores21a–21f, the material may incorporate various elastomeric fibers, such as elastane, which is manufactured under the LYCRA® trademark by E.I. duPont de Nemours and Company. Another suitable material is stretchable cotton twill having between 2 and 5% spandex fibers. In certain embodiments, suitable materials for gores21a–21fwill have a stretch that ranges at least from 2 to 5%, but the degree of stretch may vary significantly depending upon the specific structure of the various gores21a–21fand other factors related to hat10.

Although head dimensions may vary in many respects, the circumference of the head is the specific head dimension that regularly determines whether a particular hat is properly fitted. Accordingly, the circumference of crown portion20is a factor in determining whether hat10properly fits upon a head. Referring toFIGS. 1 and 2, a first arrow11and a second arrow12are depicted for reference on crown portion20. First arrow11extends in a horizontal direction and generally corresponds with a circumference of crown portion20, whereas second arrow12extends in a vertical direction. By orienting the material forming gores21a–21fsuch that a direction of stretch is substantially aligned with first arrow11, crown portion20adjusts circumferentially to accommodate the head circumferences of different individuals. That is, stretching of the material in a direction of first arrow11modifies the circumference of crown portion20in a manner that corresponds with a circumference of the head.

In addition to gores21a–21f, crown portion20may include a plurality of sections of seam tape25, a plurality of apertures26, and a button27. Seam tape25is secured to interior surface23and covers the seams between gores21a–21f. One of apertures26is formed in each of gores21a–21fto enhance the transfer of air through crown portion20. Button27is positioned on a top portion of crown portion20to mask the area where gores21a–21fconverge.

As seen inFIG. 2, a peripheral edge of a sweatband24is secured to a lower peripheral edge of crown portion20and folded upward into the interior of crown portion20.

A preferred embodiment of sweatband24is shown inFIG. 3in exploded form. Sweatband24is formed of an elongate inner piece32, having opposed longitudinal edges34,35that are folded over onto an outer surface of inner piece23to a point proximate one another to form a seam36. Once longitudinal edges34,35are folded over close to one another, longitudinal folded edges33,37are formed along the length of inner piece32.

The terms “inner” and “outer” are used herein to refer to directions with respect to the interior and exterior, respectively, of hat10. Thus, an inner portion of sweatband24is a portion that is positioned toward the interior of hat10, and the innermost portion of sweatband24will be in contact with a wearer's head. Accordingly, “outer” refers to a portion of sweatband24toward the exterior of hat10, and the outermost portion of sweatband24will be in contact with crown portion20when sweatband24is in its final position secured to crown portion24.

Inner piece32is formed of a material that is stretchable in order to deform in the presence of a tensile force to accommodate individuals with various head dimensions. The material forming inner piece32may be any generally planar material with the ability to substantially return to an original size and shape following tensile deformation. After being stretched to a reasonable degree, therefore, inner piece32is capable of substantially returning to an unstretched configuration. Inner piece23may be cut in a bias direction, or in a normal direction.

Various materials are suitable for inner piece32, including polymer, synthetic textile, and natural textile materials. In certain embodiments, inner piece32may be formed of a combination of stretchable cotton twill and spandex. In a preferred embodiment, inner piece32is formed of approximately 94% cotton and approximately 6% spandex. In another preferred embodiment, inner piece23is formed of approximately 100% polyester.

A binding38is secured to an outer side of inner piece32, the side having seam36. In certain preferred embodiments, binding38is secured to inner piece32so as to cover seam36. It is to be appreciated that in certain embodiments, binding38may be positioned above or below seam36. It is also to be appreciated that the width of binding38may vary. For example, binding38may be as wide as inner piece32, or, as seen in the embodiment shown inFIGS. 3–5, may be significantly narrower than inner piece32. Binding38is formed of an elastic material that will elastically stretch and is capable of substantially returning to its original configuration. Binding38may be cut in a bias direction, or in a normal direction.

Various elastic materials are suitable for binding38. In one preferred embodiment, binding38is formed of elastane. In another preferred embodiment, binding38is formed of approximately 60% nylon and approximately 40% rubber. Opposed longitudinal edges43,45of binding38may be machined edges in certain preferred embodiments. In other preferred embodiments, opposed longitudinal edges43,45may be folded under binding38in known fashion before binding38is secured to inner piece23.

In a preferred embodiment, stitching42is used to secure the folded portions of inner piece32to each other and binding38to inner piece32. In a preferred embodiment four rows of stitching42are used, with a row extending substantially parallel to and proximate each of longitudinal edges43,45of binding38and a row extending substantially parallel to and proximate each of longitudinal folded edges33,37of inner piece32. The row of stitching proximate longitudinal folded edge37also secures sweatband24to a lower peripheral edge of crown portion20, as can be seen inFIG. 2. It is to be appreciated that four rows of stitching are not required to secure inner piece32together and binding38to inner piece32, and that any number of rows of stitching is considered to be within the scope of the present invention.

It is to be appreciated that other methods of securing binding38to inner piece32, securing the folded longitudinal edges of inner piece32together, and securing sweatband24to crown portion22are considered to be within the scope of the invention. For example, the elements could be secured with adhesive, such as the SewFree® product supplied by Bemis Associates Inc. of Shirley, Mass. As seen inFIG. 9, binding38is secured to inner piece32with adhesive39. As seen inFIG. 10, sweatband24is secured to crown portion22with adhesive39.

In accordance with another preferred embodiment, as seen inFIGS. 6–8, inner piece32is folded about a filler piece40. Filler piece40is preferably formed of an elastic material that will elastically stretch and is capable of substantially returning to its original configuration. Various elastic materials are suitable for filler piece40including, e.g., elastane. Filler piece40may be cut in a bias direction, or in a normal direction.

Each of gores21a–21f, inner piece32, filler piece40, and binding38may be formed from a material with one-directional stretch to provide stretch in the direction of first arrow11. That is, the material forming these elements may be selected to stretch in only a single direction. When manufacturing these elements from a material with one-directional stretch, care should be taken to ensure that the direction of stretch is generally aligned with the direction of first arrow11. These elements may also be formed from a material with two-directional stretch, which provides stretch along the directions of both arrows11and12. One skilled in the relevant art will recognize that materials with two-directional stretch generally appear to stretch in any direction along the plane of the material. Accordingly, the directions of stretch in a material with two-directional stretch need not necessarily be aligned with arrows11and12, thereby simplifying the manufacturing process of these elements. When aligning the material relative to these elements, the direction of greatest stretch may be aligned with first arrow11. Each of gores21a–21f, inner piece32, filler piece40, and binding38may be formed of woven, non-woven, or knit fabrics.

By constructing sweatband24from stretchable inner piece32and elastic binding38, and, optionally, elastic filler piece40, a simple construction that effectively allows hat10to accommodate a range of head sizes can be realized.

In light of the foregoing disclosure of the invention and description of the preferred embodiments, those skilled in this area of technology will readily understand that various modifications and adaptations can be made without departing from the scope and spirit of the invention. All such modifications and adaptations are intended to be covered by the following claims.