Patent Publication Number: US-6910225-B2

Title: Hat and method for making same

Description:
FIELD OF THE INVENTION 
   The present invention relates to hats and a method for making them. More particularly, it relates to making an adjustable hat that is easy and economical to make, assemble, and display surface indicia thereon, and that is preferably constructed from a monolithic, substantially planar, semi-rigid material. 
   BACKGROUND OF THE INVENTION 
   Billed hats commonly known as “baseball hats” and “baseball caps” (collectively referred to as “baseball hats” herein) are very popular. The typical baseball hat includes a cap portion sized to rest on a wearer&#39;s head and a billed portion extending therefrom, usually at the wearer&#39;s forehead such that the billed portion shields the wearer&#39;s eyes from the sun. 
   The exposed surface of the typical baseball hat usually includes surface indicia, such as a sports team&#39;s or business&#39; name or logo. A particularly visible, and therefore desirable, location to display such surface indicia is on a front panel of the cap portion adjacent to the billed portion. Accordingly, baseball hats and the like bearing appropriate surface indicia are often used for promotional and advertising purposes. 
   The typical baseball hat includes a plurality of materials joined together. For example, the cap portion may include a plurality of mesh fabric panels sewn together around a flexible headband. The billed portion is typically planar cardboard or the like covered with a fabric material and joined to the cap portion with known means and methods. Surface indicia is applied at desirable locations, usually by embroidering or the like. 
   These materials and methods of construction necessarily increase the costs of each hat. In most cases, these costs do not justify the promotional and advertising benefits associated with a business widely distributing complementary hats bearing appropriate surface indicia. For example, a small restaurant owner would not likely give away and widely distribute these types of baseball hats bearing the name of the restaurant to potential patrons or the like. Similarly, despite the protection from the sun associated with wearing a baseball hat at an outdoor sporting event, and the high likelihood of fans wearing such a hat at the event if they had remembered to bring one from home, a vendor or advertiser is not likely to give each fan such a hat. The hats themselves are simply too expensive to justify their use as promotional items. 
   Attempts have been made to construct billed hats using economical materials such as cardboard and paper. For example, in Russian Pat. No. 19,716 to Aliferenko, a separate, central strip of paper extends between the paper bill of the hat and the paper headband to define a cap area. However, like with traditional cloth hats, considerable manufacturing efforts must be made to construct the various components of these types of paper hats and then assemble them together. These efforts necessarily increase the production costs of each hat. Moreover, the final assembled paper hat is not adjustable around the headband or in the volume of the cap portion. Also, the central strip forming the cap portion is not vividly outlined, offers only a limited surface area for displaying surface indicia thereon, and offers limited structural support, thereby limiting the rigidity of the assembled hat. Accordingly, wearer comfort, ease of use, and the promotional benefits of the hat are compromised. Moreover, these types of hats are not reversible by their wearers. 
   More recently, attempts have been made to reduce the production costs of hats by making them from a single sheet of cardboard or the like. However, these attempts to reduce the production costs have also compromised the quality and fit of the hat. For example, U.S. Pat. No. 5,010,590 to Haber et al. discloses a visor having a display panel adjacent to a bill with adjustable straps extending from the bill to form a headband. To wear the visor, the wearer must detach the hat from the rectangular sheet of paper-type material, and join the straps together to form the headband. Since the headband is the only means for securing the visor to its wearer, it must fit snuggly around the wearer&#39;s head. In practice, the snug fit is uncomfortable for the wearer over prolonged use, and it places significant strain on the straps leading to their premature wear. Moreover, there is no cap portion to protect the wearer&#39;s head from the sun and provide additional space for surface indicia. 
   In addition, known baseball hats and the like that are constructed from a single sheet of material have several limitations. For example, U.S. Pat. No. 6,092,239 to Pogrebitsky et al. and U.S. Pat. No. 5,428,842 to Wise disclose baseball hats having left and right straps extending from a billed portion. The cap portion is defined by five elongate strips of material extending from the billed portion between the left and right straps. The elongate strips are joined at a point near their opposite ends to define a cap portion, and the left and right strips are joined to each other and the end of a central elongate strip to define each hat&#39;s headband. 
   These types of hats require numerous die-cuts in the planar material to form the elongate strips, and they also require at least one alignment hole or the like to be cut into each elongate strip, thereby increasing the assembly time and related costs of each hat. Moreover, because of spacing requirements between the various components forming each hat, a significant portion of the planar material is wasted when forming the hat. In addition, the volume of the cap portion in this type of hat is not adjustable, and considerable time, effort, and some cases even special fasteners are required to fully assemble each hat. In practice, a patron receiving these types of hats in unassembled form, such as at a sporting event, may find it too difficult or too confusing to assemble. Accordingly, he may simply throw such a hat away rather than use it, thereby destroying any promotional value offered by the hat. 
   Moreover, the numerous elongate strips that form the cap portion of these types of hats make it difficult to place an easily viewable continuous surface indicia, such as a large logo or the like, on the cap portion of the hat. For example, a large logo would have to be printed onto each elongate strip in segments such that when the cap is assembled, they would align to form the logo. It can be difficult for a wearer to consistently assemble and align such strips in such a manner as to prevent distracting the viewer&#39;s view of the overall logo. Moreover, such structures to not lend themselves to being reversible, thereby precluding a wearer from selecting between two different patterns of surface indicia to display on the hat. It can be difficult for a wearer to consistently assemble and align such strips in such a manner as to prevent distracting the viewer&#39;s view of the overall logo. 
   SUMMARY OF THE INVENTION 
   Accordingly, despite the improvements offered by known baseball hat designs, there remains a need for an economical and easy to manufacture billed hat that has an adjustable cap volume, and that is easy and economical to manufacture and assemble, preferably from a monolithic, substantially planar, semi-rigid material such as cardboard or the like, and that allows a large amount of surface indicia to be easily applied and displayed. In addition to other benefits that will become apparent in the following disclosure, the present invention fulfills these needs. 
   The present invention is a hat, which is preferably a baseball hat, constructed from a sheet of material having a base portion, which preferably forms a bill, a left and right headband portion, and a central cap portion extending therefrom. The distal ends of the left and right headband portions include an adjustable fastener to detachably secure these portions together to form an adjustable headband. 
   The central cap portion preferably includes left and right ends toward the distal ends of the cap portion. These ends each include an adjustable fastener for detachably and adjustably securing the left end to the left headband portion and the right end to the right headband portion. The cap of the hat is defined by the cap portion between the left and right headband portions, and a wearer may adjust the size of the cap by moving the adjustable fasteners securing the ends to the headband portions. 
   In a preferred embodiment, the hat is die-cut from a sheet of material, such as cardboard, and the various portions of the hat are defined using three cuts: one cut between the left and center portion, one cut between the right and center portions, and one perimeter cut defining the overall outline of the hat. More preferably, the hat also includes three fold lines: one each between the billed portion and each of the left, right and center portions. 
   The left and right portions have an outer surface that is wide enough to display surface indicia thereon, defining left and right surface indicia panels, respectively. Moreover, the center cap portion has an outer surface that includes a forward facing surface indicia panel adjacent to the billed portion and a rearward facing surface indicia panel toward the distal end of the center cap portion. The left, right, forward-facing, and rearward-facing surface indicia panels are sized and shaped to be aesthetically interesting and pleasing, but also to allow easy viewing of the surface indicia placed thereon. Surface indicia may also be placed on the upper and lower sides of the billed portion. 
   In a preferred embodiment, the hat is reversible such that a wearer may select between two different surface indicia to display by electing which of two sides of the semi-rigid material to display as the outer surface of the hat. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is an isometric, front view of a fully assembled baseball hat manufactured in accordance with a preferred embodiment of the present invention showing one possible side of the substantially planar material forming an outer surface of the hat. 
       FIG. 2  is a top plan view of a substantially planar material cut in accordance with a preferred embodiment of the present invention, that when assembled in accordance with a preferred embodiment of the present invention, forms the baseball hat of FIG.  1 . 
       FIG. 3  is an isometric, rear side view of the hat of  FIG. 1  with the left and right headband portions also shown unattached in broken lines. 
       FIG. 4  is a rear plane view of the hat of FIG.  1 . 
       FIG. 5  is an isometric, front view of an alternative preferred baseball hat in accordance with a preferred embodiment of the present invention. 
       FIG. 6  is a bottom plan view of the substantially planar material of FIG.  2 . 
       FIG. 7  is an isometric, rear side view of the hat of  FIG. 5  with the left and right headband portions also shown unattached in broken lines. 
       FIG. 8  is an isometric, rear side view of the fully assembled baseball hat manufactured in accordance with a preferred embodiment of the present invention showing a second possible side of the substantially planar material forming the outer surface of the hat. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
   An adjustable hat  10  constructed from a sheet of material  12  having an exterior  81  surface, an interior surface  83 , a base portion, which is preferably a billed portion  14  with a left and right headband portion  16 ,  18 , respectively, and a central cap portion  20  extending therefrom is disclosed in  FIGS. 1-8 . 
   A. Preferred Hats 
   As best shown in  FIGS. 1 and 2 , the billed portion  14 , preferably has an arcuate outer edge  22  opposite the headband portions  16 ,  18  and central cap portion  20 . The left and right headband portions  16 ,  18  are secured at one end to the billed portion  14 , preferably at fold lines A and B, respectively. The opposite ends  24   a,    24   b  of the headband portions  16 ,  18  include an adjustable fastener  26  to detachably secure these portions  16 ,  18  together to form an adjustable headband  28 . For example, one of the left and right headband portions  16 ,  18  (left headband portion  16  is shown in  FIGS. 1 and 2 ) preferably includes a notched tab  30 , while the other of the left and right headband portions (right headband portion  18  is shown in  FIGS. 1 and 2 ) includes a plurality of space-apart slots  32   a-e  for matingly engaging the notched tab  30 , thereby detachably securing the headband portions  16 ,  18  together to form an adjustable headband  28 . 
   The central cap portion  20  is secured on one end to the billed portion  14 , preferably at fold line C, and is preferably shaped to be symmetrical about a longitudinal centerline of the cap portion. More preferably, the cap portion forms a generally t-shaped portion  40  having left and right ends  42 ,  44 , respectively, toward the distal end  46  of the central cap portion  20 . The left and right ends  42 ,  44  each include an adjustable fastener  48   a ,  48   b,  respectively, for detachably and adjustably securing the left end  42  to the left headband portion  16  and the right end  44  to the right headband portion  18 . For example, the left and right ends  42 ,  44  each preferably include a notched tab  50   a ,  50   b , respectively, while the respective headband portions  16 ,  18  each include a plurality of space-apart slots  60   a ,  60   b  and  62   a ,  62   b,  respectively, for matingly engaging their respective notched tabs  50   a ,  50   b,  thereby detachably securing the central cap portion  20  to the adjustable headband  28 . 
   Preferably, the left and right headband portions  16 ,  18  have a first surface  70  that is wide enough to display surface indicia  71  thereon, defining left and right surface indicia panels  72 ,  74 , respectively. Moreover, the center cap portion  20  has a first surface  70  that includes a forward-facing surface indicia panel  76  adjacent to the billed portion  14  and a rearward-facing surface indicia panel  78  toward the distal end  46  of the center cap portion  20 . The first surface  70  forms the exterior surface  81  of the hat thereby displaying surface indicia  71 . The left, right, forward-facing and rearward-facing surface indicia panels  72 ,  74 ,  76 ,  78  are sized and shaped to be aesthetically interesting and pleasing, but also to allow easy viewing of the surface indicia  71  placed thereon. Surface indicia may also be placed on the upper side  80  and lower side  82  of the billed portion  14 . 
   To assemble the hat  10  as shown in  FIG. 1  from its substantially planar configuration shown in  FIG. 2 , the assembler folds the central cap portion  20  upward along fold line C. The assembler then folds the left and right headband portions  16 ,  18  sideways along fold lines A, and B, respectively. As best shown in  FIG. 3 , the assembler then inserts the notched tabs  50   a ,  50   b  of the left and right ends  42 ,  44  of the central cap portion  20  into the respective mating slots (slots  60   b  and  62   b  are shown in  FIG. 3 ) on the left and right headband portions  16 ,  18 . The assembler then joins the left and right headband portions  16 ,  18  together by engaging notched tab  30  into one of the respective mating slots (slot  32   a  is shown in FIG.  3 ). 
   It can be appreciated that the size, or volume, of the cap of the hat, which is defined by the area under the central cap portion  20 , can be easily adjusted by selecting the desired mating slots  60   a ,  60   b ,  62   a ,  62   b  into which the notched tabs  50   a ,  50   b  of the left and right ends  42 ,  44  are inserted. Moreover, the diameter of the central cap portion  20  can be easily adjusted to a desired size by selecting the appropriate slot  32   a-e  into which the notched tab  30  of the headband portion is inserted. 
   In addition, as best shown in  FIGS. 7 &amp; 8 , the second surface  73  can also include surface indicia  75  thereon. It can be appreciated that the adjustable fasteners  48   a ,  49   b  operably engage their respective components, such as the notched tabs  30 ,  50   a ,  50   b , operably engage their respective mating slots  32   a-e ,  60   a-b ,  62   a-b , respectively, such that the second surface  73  can also form the exterior surface  81  of the hat as shown in FIG.  7 . Accordingly, it can be appreciated that the hat can be assembled such that either the first surface  70  ( FIG. 1 ) or second surface  73  ( FIG. 7 ) is displayed. Accordingly, in such an embodiment, the assembler has a choice when assembling the hat as to which surface indicia  71  or  75  to display, thereby making the hat reversible. 
   Such assembly is so quick and easy, that when presented with the hat  10  in the unassembled form of  FIG. 2 , most assemblers can figure out how to assemble and adjust it for comfort with no specific instructions. Accordingly, the hat  10  may be economically distributed in unassembled form as a promotional item with a high likelihood that recipients will assemble and wear it. In such case, the labor costs associated with assembling each hat are avoided. 
   An alternative preferred embodiment of the hat  10 ′ is disclosed in  FIGS. 5 and 6 . This embodiment has substantially the same basic elements, construction and assembly of the previously described embodiment. Accordingly, in order to avoid undue repetition, unless specifically identified otherwise below, reference numerals refer to like numbered elements having a like orientation and configuration as those elements identified in the discussion of the first preferred embodiment. 
   In this embodiment, the central cap portion  20  includes fold line D, spaced apart from and substantially parallel to fold line C to define a substantially planar forward facing surface indicia panel  76  on the fully assembled hat  10 ′ as shown in FIG.  5 . This substantially planar forward facing surface indicia panel  76  allows the surface indicia  71  on that panel  76  to be more easily viewed when the hat  10 ′ is worn. 
   B. Preferred Manufacturing Method 
   The hat  10 ,  10 ′ according to the present invention is preferably manufactured according to the following process: 
   First, desired surface indicia  71 ,  75  is placed on a sheet of semi-rigid material  12 , such as cardboard, plastic, paper, tissue, or the like. Preferably, the sheet of material  12  is a monolithic structure. More preferably, the surface indicia  71  is sized, shaped and oriented to occupy the areas of the sheet of material that will ultimately become the left, right, forward facing, and rearward facing surface indicia panels  72 ,  74 ,  76 ,  78  and the upper and lower sides  80 ,  82  of the billed portion  14 . Of course, if desired, one or more of these areas can not have surface indicia thereon. 
   The sheet of material  12  is then cut, preferably using conventional die cutting techniques, using three cuts: one cut between the left and center portion, shown as solid line  100  in  FIG. 2 , one cut between the right and center portions, shown as solid line  102  in  FIG. 2 , and one perimeter cut defining the overall outline of the hat, and shown as solid line  104  in FIG.  2 . Preferably, folds A, B, C, and D ( FIG. 5 , alternative preferred embodiment only) and slots  32   a-e ,  60   a-b , and  62   a-b  are also added as shown in FIG.  2 . Preferably, an industrial manufacturing blanking die is used to make all such cuts in one pass. 
   It can be appreciated that the four essential portions  14 ,  16 ,  18 ,  20  of the present hat  10 ,  10 ′ can be formed using three cuts  100 ,  102 ,  104 , and that no material is wasted between the various portions. The resulting hats  10 ,  10 ′ are easy and economical to manufacture, and are particularly well suited for distribution as promotional or advertising items. 
   In view of the wide variety of embodiments to which the principles of the invention can be applied, it should be apparent that the detailed embodiments are illustrative only and should not be taken as limiting the scope of the invention. For example, the shape and overall perimeter of the cuts  100 ,  102 ,  104  may be modified for to achieve a hat having a desired shape when assembled. Moreover, the number of ends  42 ,  44  extending from the central cap portion  20  can be increased, and the shape, orientation, and number of folds C and D ( FIG. 5 ) can be modified or increased as needed or desired. Rather, the claimed invention includes all such modifications as may come within the scope of the following claims and equivalents thereto.