Patent Publication Number: US-2013247281-A1

Title: Self-Adhering Disposable Headwear Liner

Description:
BACKGROUND OF THE INVENTION 
     This invention relates generally to the field of headwear liners or sweatbands, and more particularly to such headwear liners that are temporarily affixed to the forehead or sweatband area of a hat, visor, helmet or other type of headwear, the liner being formed of an absorbent material to absorb perspiration, oils, sunscreens, cosmetics or the like. 
     Many types of headwear have internal bands that encircle the wearer&#39;s head, usually resting on the forehead. For example, in a baseball cap, the internal band is positioned around the base of the crown with its lower edge substantially even with the bill of the cap. These permanently mounted bands easily become soiled over time, especially when the headwear is worn for sports, manual labor or other types of energetic behavior. While certain headwear is washable, many types are not, and thorough cleaning of washable headwear is difficult. It is known to affix disposable liners or sweatbands inside the headwear, usually with an adhesive that is sufficiently strong to retain the disposable liner in the headwear but which allows the disposable liner to be removed and replaced when it becomes excessively soiled. 
     Examples of sweatbands or sweatband liner devices for headwear are shown in U.S. Pat. No. 1,986,312 to Wilson, U.S. Pat. No. 2,003,886 to Hoffeld, U.S. Pat. No. 4,274,157 to Boden, U.S. Pat. No. 4,393,519 to Nocastro, U.S. Pat. No. 4,394,782 to Wasson, U.S. Pat. No. 4,406,021 to Bloom, U.S. Pat. No. 4,468,817 to Nunnery et al., U.S. Pat. No. 4,502,156 to Wishman, U.S. Pat. No. 4,547,903 to Brown et al., U.S. Pat. No. 4,630,317 to Brown et al., U.S. Pat. No. 4,833,734 to Der Estephanian, U.S. Pat. No. 4,856,116 to Sullivan, U.S. Pat. No. 4,941,210 to Konucik, U.S. Pat. No. 4,947,488 to Ashinoff, U.S. Pat. No. 4,949,404 to Fekete, Sr., U.S. Pat. No. 5,022,095 to Fleury, U.S. Pat. No. 5,025,504 to Benston et al., U.S. Pat. No. 5,046,196 to Sullivan, U.S. Pat. No. 5,058,210 to Tivis, U.S. Pat. No. 5,088,126 to Mathis, U.S. Pat. No. 5,317,761 to Piche, U.S. Pat. No. 5,432,955 to Plotka et al., U.S. Pat. No. 5,553,326 to Moore, U.S. Pat. No. 5,566,395 to Nebeker, U.S. Pat. No. 5,613,248 to Young, U.S. Pat. No. 5,632,046 to Green et al., U.S. Pat. No. 6,477,715 to Shin, and U.S. Pat. No. 6,738,985 to Hahn et al. 
     It is an object of this invention to provide disposable, self-adhering liners with improved construction that fit virtually all headwear for adults and children. It is an object of this invention to provide a removable, self-adhering and disposable headwear liner that has an improved construction such that the absorption and evaporation efficiency and comfort of the liner are increased. 
     SUMMARY OF THE INVENTION 
     The self-adhering and disposable headwear liner or sweatband is a band-shaped assembly that is adapted to be temporarily mounted onto the permanent internal band of headwear, or directly onto a forehead or forefront portion of headwear, such as caps, hats, visors, helmets or the like. The liner is a multi-layer assembly comprising in a preferred embodiment a topsheet layer, an absorbent core layer, moisture barrier layer, an adhesive layer, and a release layer. In an alternative embodiment the adhesive layer may be replaced by a double-sided tape layer. In another alternative embodiment an adhesive layer may be positioned on the both sides of the moisture barrier layer. The absorbent layer is significantly thicker than the other layers, as this layer also provides cushioning for comfort. The topsheet layer possesses high wicking properties, such that the topsheet layer itself remains relatively dry and moisture absorbed into the absorbent core layer is separated from the user&#39;s skin. 
     The topsheet layer, the absorbent core layer and most preferably the moisture barrier layer are assembled into a cohesive unit by a punch-bonding technique, whereby a punch having a plurality of post members creates a plurality of spaced, straight, open channels, holes or bores extending completely through the topsheet layer and the absorbent core layer and partially through the moisture barrier layer. The layers are thus bonded together, the punching technique resulting in the fibers or materials of each adjacent layer becoming mechanically interlocked and intertwined. With this method of manufacture, no adhesives which might interfere with the absorption efficiency of the liner are required to join the layers, the adhesive layer being present only to adhere the liner to the headwear. In an alternative embodiment, only the topsheet layer and the absorbent core layer are punch bonded together, the moisture barrier layer being adhesively joined to the absorbent core layer. 
     The channels created in the liner provide conduits for better and more rapid absorption of perspiration and other liquids, since the channels allow for direct passage of moisture into the interior and lower portions of the absorbent layer. The channels also provide conduits for better and more rapid evaporation of perspiration and other liquids from the headwear liner. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is cross-sectional view of an embodiment of the headwear liner, wherein the topsheet layer, absorbent core layer and moisture barrier layer are punch-bonded together, and the adhesive layer is applied to the underside of the moisture barrier layer. 
         FIG. 2  is a cross-sectional view of an alternative embodiment of the headwear liner, wherein the topsheet layer, absorbent core layer and moisture barrier layer are punch-bonded together, and a double-sided tape member is joined to the underside of the moisture barrier layer. 
         FIG. 3  is a cross-sectional view of an alternative embodiment of the headwear liner, wherein the topsheet layer and absorbent core layer are punch-bonded together, and the moisture barrier layer is adhesively bonded to the absorbent core layer. 
         FIG. 4  is a view of the headwear liner applied onto the interior band of headwear. 
         FIG. 5A  is a view of self-encircling headwear liner, shown in the disconnected configuration. 
         FIG. 5B  is a view of the self-encircling headwear liner of  FIG. 5A , shown in the connected configuration. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     With reference to the drawings, the invention will now be described in detail with regard for the best mode and the preferred embodiment. In a broad sense, the invention is a disposable headwear liner or sweatband adapted to be temporarily attached within headwear such that the liner makes direct contact with the wearer to absorb perspiration, oils, sunscreen, cosmetics or other such liquids, referred to herein generally as moisture. In this manner the original internal band of the headwear is protected from soiling and the temporary liner may be removed and replaced when it becomes excessively soiled. As used herein, the bottom or underside of the liner is to be taken to mean the side of the liner that is adhered to the headwear and the top or upper side of the liner is to be taken to mean the side of the liner that remains exposed after attachment of the liner to the headwear and which contacts the user&#39;s skin. The thicknesses of the layers in the drawings are for illustrative purposes and are not to scale. 
     As will be described in more detail, the preferred embodiment is a self-adhering, disposable headwear liner assembly  13  having a topsheet layer  30 , an absorbent core layer  50  and a moisture barrier layer  34  non-adhesively joined to each other, and a plurality of well-defined, straight, open bores, holes or channels  51  extending through the topsheet layer  30  and the absorbent core layer  50  and extending partially into the moisture barrier layer  34 , wherein the topsheet layer  30 , the absorbent core layer  50  and the moisture barrier layer  34  each comprise fibers and the fibers of adjacent layers are mechanically interlocked to join the topsheet layer  30  to the absorbent core layer  50  and the absorbent core layer  50  to the moisture barrier layer  34 , and an adhesive layer  35  joined to the moisture barrier layer  34  capable of securing the liner  13  to the internal band  10  of headwear  12 . 
     The liner  13  is an elongated, generally rectangular, flexible member, the edges and sides of which may be straight, curved or of varying configuration and having angled or rounded corners. The dimensions of the liner  13  may vary, but representative and non-limiting dimensions for a suitable liner  13  may be approximately twelve inches in length, approximately one to 1.5 inches in width and one eighth to one quarter inches in thickness. The liner  13  may be longer, shorter, wider, narrower, thinner or thicker than these dimensions. 
     As seen in  FIG. 1 , the preferred embodiment of the disposable headwear liner  13  comprises a topsheet layer  30 , an absorbent core layer  50 , a non-absorbent moisture barrier layer  34 , an adhesive layer  35 , and a removable release layer  36 . To adhere the liner  13  to headwear  12 , the release layer  36  is removed to expose the adhesive layer  35 , and the liner  13  is pressed against the internal band  10  of the headwear  12  or pressed against the forward portion of headwear  12  not having an internal band, as shown in  FIG. 4 . 
     The flexible topsheet layer  30  is liquid permeable and possesses high moisture wicking characteristics, and is preferably non-moisture absorbing. The topsheet layer  30  is significantly thinner than the absorbent core layer  50 . The topsheet layer  30  may be composed of many suitable natural or synthetic materials, such as polypropylene (PP) or cotton for example. A preferred embodiment for the topsheet layer  30  is a spunbound (S) non-woven layer of polypropylene. Other suitable materials include but are not limited to polyester (PET) spunbound nonwoven, PP meltblown (M) nonwoven, SMS nonwoven, SMMS nonwoven, wetlaid nonwoven, carded thermalbond nonwoven using PP, PET, rayon, cotton or other fibers alone or in combination, carded spunlace nonwoven using PP, PET, rayon, cotton or other fibers alone or in combination. The basis weighting of the topsheet layer  30  is preferably from 10 gsm to 50 or more gsm, and a gsm of 20 has been found to be suitable. Because of its excellent moisture wicking properties, the topsheet layer  30  remains drier than absorbent core layer  50  since the moisture passes through the topsheet layer  30  rather than being absorbed therein. 
     The flexible absorbent core layer  50  is significantly thicker than the other layers, preferably being from 50 to 500 or more gsm, with a gsm of 185 having been found to be suitable. The absorbent core layer is highly absorbent of liquids. A preferred embodiment for the core layer  50  is a cellulosic fluff pulp. Other suitable materials include but are not limited to cotton fiber, linters, recycled textile fiber, super-absorbent filler, a combination of these materials, or any of various nonwovens made with a combination of these fibers. The absorbent core layer  50  may be composed of a single layer or of multiple layers of individual absorbent layers of identical or different materials. The absorbent core layer  50  is preferably composed of a material and structure such that there is no or only minimal swelling of the absorbent core layer  50  when it is saturated with moisture. 
     The flexible moisture barrier layer  34  is non-absorbent and non-permeable to liquids, moisture and/or moisture vapor. The moisture barrier layer  34  also provides structural integrity to the assembled liner  13 , being composed of a flexible material such that the moisture barrier layer  34  is inherently stronger and more stable than the topsheet layer  30  and the absorbent core layer  50 . A preferred embodiment for the moisture barrier layer  34  is a polyethylene (PE) film with a basis weight of 25 gsm, although gsm&#39;s of between 10 and 50 or more may be suitable. Other suitable materials include but are not limited to PP film, low density PE film, high density PE film, and polylactic acid film. 
     In this embodiment the adhesive layer  35  is an adhesive applied to the underside of the moisture barrier layer  34  and may comprise any adhesive capable of joining the liner  13  to the headwear internal band  10  in a strong yet releasable manner such that the liner  13  will not self-detach yet may be easily removed and replaced. The adhesive must be suitable for use in high temperature and high-moisture environments foreseen likely to occur during use of the headwear  12  in sporting events and the like. Many pressure sensitive adhesives, contact adhesives or hot melt adhesives possessing the required characteristics will be known those of ordinary skill in the art. 
     The removable release layer  36  is a temporary protective layer for the adhesive layer  35  and is removed and discarded prior to application of the liner  13  to the headwear  12 , as shown in  FIG. 4 . Any of the common paper or polymer film members coated with a release agent, such as silicone, may be utilized. 
     The topsheet layer  30 , absorbent core layer  50  and moisture barrier layer  34  are most preferably connected together without adhesives using a punch bonding technique of manufacture. In punch bonding, a plurality of small pins or posts are pressed into and through the layers, whereby the fibers composing adjacent layers become mechanically interlocked or intertwined and secure the adjacent layers against separation. The posts pass completely through the topsheet layer  30  and the absorbent core layer  50 , while preferably passing only partially into but not completely through the moisture barrier layer  34 . The posts possess a minimum diameter of preferably from about 2 mm to 6 mm such that upon withdrawal from the layers well-defined, straight, cylindrical holes, bores or channels  51  of substantially the same diameter remain in the liner  13 , the channels  51  extending through the top sheet layer  30 , through the absorbent core layer  50  and partially through the moisture barrier layer  34 . The channels  51  allow moisture to pass directly into the interior of the absorbent core layer  50  to be absorbed laterally by the interior and lower portion of the absorbent core layer  50 . This greatly increases the absorption efficiency of the core layer  50  since moisture is now absorbed directly into the interior of the core layer  50  through the channels  51  in addition to being absorbed directly through the upper surface of the absorbent core layer  50 . Furthermore, the channels  51  increase the evaporation rate of moisture from the liner  13  when the headwear  12  is removed. With the dimensions not meant to be limiting, providing rows of channels  51  spaced approximately 0.25 inches apart, with the channels being spaced approximately 0.25 inches in each row, has been found to be a suitable and efficient distribution. 
     In an alternative embodiment shown in  FIG. 2 , the liner  13  comprises a topsheet layer  30 , absorbent core layer  50  and moisture barrier layer  34  non-adhesively joined together into a layered assembly, the assembly possessing channels  51  as previously described. A double-sided tape is joined to the underside of the moisture barrier layer  37 , the double-sided tape comprising a carrier layer  37 , which may comprise for example a paper or polymer film layer, sandwiched between two adhesive layers  35 . The carrier layer  37  may be composed of a material that is impermeable to liquid, moisture or moisture vapor. As in the earlier embodiment, the release layer  36  is temporarily applied to the bottom adhesive layer  35  and removed prior to affixation of the liner  13  to the interior band  10  of the headwear  12 . 
     Still another embodiment is illustrated in  FIG. 3 , where the liner  13  comprises a topsheet layer  30  and absorbent core layer  50  non-adhesively joined together into a layered assembly, the assembly possessing channels  51  that extend through the topsheet layer  30  and the absorbent core layer  50 . The moisture barrier layer  34  is provided with adhesive layers  35  on its upper side and underside, such that the moisture barrier layer  34  is adhesively bonded to the underside of the absorbent core layer  50 . As in the earlier embodiments, the release layer  36  is temporarily applied to the bottom adhesive layer  35  and removed prior to affixation of the liner  13  to the interior band  10  of the headwear  12 . 
       FIGS. 5A and 5B  show an embodiment for the liner  13  that enables the liner  13  to also be used as a headband without affixing it to headwear. The free ends of the liner  13  are provided with hook-and-loop type fastener elements  19 , with one hook-and-loop component attached to the top of the liner  13  and the other hook-and-loop component attached to the bottom of the liner  13 . With this construction, the liner  13  may be joined to itself to form a complete annular band which can be worn on the user&#39;s head. The release layer  36  may be provided with printed indicia, such as team logos, brand names, slogans, etc. 
     The liner  13  may be provided with anti-microbial agents, coloring, designs, textures, temperature- or moisture-sensitive inks that react to heat and moisture when the liner  13  is worn, cooling agents, etc. The release layer  36  may be provided with tabs, slits to enable easier removal of the release layer  36  from the adhesive layer  35 , and may extend slightly beyond one or both ends of the adhesive layer  35 . The adhesive layer  35  may be discontinuous or not fully coextensive with the underside of the moisture barrier layer  34 . Magnets may be incorporated into the liner  13  to improve concentration. 
     It is understood that equivalents and substitutions for elements set forth above may be obvious to those of ordinary skill in the art, and therefore the true scope and definition of the invention is to be as set forth in the following claims.