Patent Publication Number: US-2013232664-A1

Title: Military hat construction

Description:
CLAIM OF PRIORITY 
     The present application is based on and a claim of priority is made under 35 U.S.C. Section 119(e) to a provisional patent application that is currently pending in the U.S. Patent and Trademark Office, namely, that having Ser. No. 61/601,805 and a filing date of Feb. 22, 2012, and which is incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     A military hat comprising a frame including a head band and a grommet used to support and at least partially configure a flexible material covering for the hat. The invention includes a stay that defines a frontal portion of the hat along with a visor, and is structured to support the grommet in a manner which enables a front surface of the stay to be substantially smooth and to offer a substantially uninterrupted appearance, for purposes of eliminating any disfiguring or unsightly protrusions which might be observed on the material covering the front portions of the hat, especially above the visor. 
     2. Description of the Related Art 
     Military hats and in particular, uniform hats of the type worn by military personnel in the United States, and throughout many countries of the world, have been extensively used for many years. These types of hats typically include a frame and a visor formed of an at least partially or semi-rigid material that extends outwardly from a front portion or frame of the hat. Most often, a fabric material or other typically flexible material is disposed in overlying relation to the frame of the military hat so as to cover the exposed and interior portions thereof, and to protect the head of the wearer from the surrounding elements, to at least some extent. It is also common to dispose a symbolic or decorative emblem, awards, indicia or other representation on an exterior surface of the front portion of the hat above the visor and in clear view so that one&#39;s position and importance can readily be gleaned. 
     One example of such a uniform hat or military cap construction is disclosed and described in U.S. Pat. No. 4,097,934 to Bernard Weinstein, a named inventor herein, which issued in 1978. As disclosed, the frame of this hat includes an annular, flexible but rigid material “stretching band” disposed to extend along the upper or outer periphery of the cover so as to facilitate the support and shaping thereof. This stretching band is supported by a stay structure disposed on the hat frame and at least partially defining the frontal portion thereof. Support and intended positioning of the stretching band is accomplished through the provision of a band holder. As clearly represented of  FIG. 8  of this patent, a band support structure is connected to the upper or outer periphery of the stay by stitching or other appropriate connection. The stretching band passes through the interior of this supporting structure so as to be properly positioned for the support, stretching and/or configuring of the overlying cover. 
     While this type of uniform or military hat construction is well accepted and may still be in wide use, one possible disadvantage associated therewith is the structuring or forming of the stretch band holder in a manner which extends over and/or onto the front surface or face of the supporting stay. As a result, at least a portion of the band holder projects into and thereby visually deforms to some minor extent, the portion of the cover which overlies the stay. Accordingly, when viewing the front portion of the hat, some detectable deformation and/or imperfections, such as crease(s) are clearly visible. This, in turn, detracts from the intended and preferred smooth and “clean” or uninterrupted appearance of the front of the uniform hat, and perhaps especially as well as from the decorative or symbolic emblem or indicia form thereon. 
     Accordingly, there is a need in this field of art for a uniform hat and/or military hat having an improved construction that is capable of eliminating or significantly reducing the possibility of visual imperfections appearing in the front covering on the hat disposed above the visor. If any hat were made with such an improved construction, the hat would also still provide stable, reliable support for and at least partially configure the overlying cover as it extends about the interior and upper periphery thereof. 
     SUMMARY OF THE INVENTION 
     The present invention is intended to present a solution to these and other needs that remain in this field of art, and as such, is directed to a uniform or military hat construction comprising a frame typically including an annular headband. In addition, a visor formed of a substantially rigid material extends outwardly from and at least partially defines a frontal portion of the frame. The stay is connected to the frame substantially adjacent to the visor so as to extend outwardly or upwardly there from. As such the stay also at least partially defines a frontal portion of the frame and the military hat. 
     A grommet comprises a metallic or other appropriate material band formed into a somewhat annular configuration and connected in supported relation on the stay. As typically disposed and structured, the grommet is used to support a fabric or other flexible material cover which extends over the top and front of the hat frame in at least partially enclosing relation to the interior thereof. Moreover, a front portion of the cover extends over a front surface of the stay and may have an emblem or other structure connected to the frame in overlying relation to an outer surface of the cover, which overlies the stay. Therefore, the grommet serves not only to support the flexible material cover above the frame, but also serves to stretch and/or configure a peripheral portion of the cover which overlies the interior of the military hat, when assembled. 
     Additional structural features of the military hat construction of the present invention include at least one preferred embodiment of the stay comprising an elongated channel formed on a rear face of and extending along and in adjacent relation to an upper or outer most periphery of the stay. It is to be understood that as used herein, the term “outer or upper”, when referring to the periphery of the stay, is intended to describe the peripheral portion of the stay which is spaced from and substantially oppositely disposed to the visor. 
     The channel is structured to support and at least partially enclose a portion of the length of the grommet so as to maintain the grommet in supporting, configuring relation to the flexible material cover. Cooperative structural features of the stay and channel serve to support and position the grommet in a manner which defines a front surface or face of the stay as having an at least partially smooth and/or substantially uninterrupted configuration. Accordingly, the uninterrupted configuration of the front face of the stay serves to eliminate of significantly reduce the possibility of observable, unintended deformations or disfigurements of the front portion of the cover which overlies the front surface of the stay above the visor. Such observable deformations of military or uniform hats are known to exist in conventional hat structures and may be caused by portions of the stay and/or grommet support which inadvertently disfigure the frontal portion of the flexible material cover. As a result, the overall appearance of the military hat specifically including, but not limited to the frontal portion thereof, is significantly enhanced. 
     Additional structural features of one or more preferred embodiments of the stay include the supporting channel having oppositely disposed open ends through which grommet is positioned, when supported on the stay. Moreover, each of the oppositely disposed open ends of the channel comprises both a front end segment and a rear end segment. As such, the front end segment is recessed inwardly along the length of the channel relative to the rear end segment. As a result, unsightly protrusions or projections underlying the front portion of the cover which might be visually observable when viewing the front of the hat are eliminated. As a result and as set forth above the frontal portion of the hat cover will provide a clean, uninterrupted appearance by eliminating any projections or protrusions which would normally be present utilizing a stay construction of known or conventional design. 
     In addition, the visually clean, uninterrupted appearance of the front portion of the cover is also at least partially the result of the structure and position of the channel and the grommet supported thereby. More specifically, the channel is disposed rearward of the front face or on or adjacent the rear face of the stay as set forth in greater detail hereinafter. Therefore, the structure and disposition of the channel facilitates the support of the grommet by passing a portion of its length through the channel and though the oppositely disposed open ends of the channel. As a result, the grommet is disposed in an overlying orientation of the rear end segments of the open ends and a concurrent underlying orientation relative to the front end segments of the oppositely disposed open ends. 
     Further, in at least one preferred embodiment the stay is formed of a plastic material being at least somewhat flexible but having sufficient rigidity to define the upstanding frontal portion of the military hat as it at least partially supports the cover via the grommet. In this preferred embodiment the stay is formed of a front panel and a rear panel disposed in overlying relation to one another. The overlying panels are interconnected at least by an elongated peripheral connecting seam extending along the outer or upper longitudinal periphery of the stay. Also, the front and rear panels of the stay also may be secured in overlying relation to one another by a plurality of additional seams spaced from one another and from the peripheral connecting seam. 
     Yet another preferred embodiment of the stay includes a construction which is operationally similar, at least in terms of supporting the grommet in the intended position. Also, this additional preferred embodiment of the stay provides a clean visual appearance of the frontal portion of the military hat when fully assembled, by the elimination of any protrusions, projections or like disfiguring structure which may be unintentionally viewed when looking at the front portion of the hat. As such, at least one preferred embodiment of the stay may be formed of at least one panel having a supporting channel secured to a rear face or surface thereof. More specifically, the channel includes an outer or upper connecting seam and an inner or lower connecting seam. Both the upper and lower seams extend continuously along the length of the channel and terminate at the oppositely disposed open ends. As with the other preferred embodiment of the stay described above, the opposite open ends of the channel may include a recessed front end segment in order to avoid any unsightly projections, protrusions, etc. when viewing the front portion of the military hat. Depending upon the material from which the stay is formed, the spaced apart connecting seams can be formed by a stitching type connection. 
     These and other objects, features and advantages of the present invention will become clearer when the drawings as well as the detailed description are taken into consideration. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a fuller understanding of the nature of the present invention, reference should be had to the following detailed description taken in connection with the accompanying drawings in which: 
         FIG. 1  is a perspective view and partial phantom of a military hat construction incorporating one preferred embodiment of a grommet supporting stay. 
         FIG. 2  is a front plan view of the stay of the embodiment of  FIG. 1 . 
         FIG. 3  is a left side view of the embodiment of  FIG. 2 . 
         FIG. 4  is a top view of the embodiment of  FIG. 2 . 
         FIG. 5  is a right side view of the embodiment of  FIG. 2 . 
         FIG. 6  is a bottom view of the embodiment of  FIG. 2 . 
         FIG. 7  is a rear plan view of the embodiment of  FIG. 2 . 
         FIG. 8  is a front plan view of yet another preferred embodiment of the stay which may be incorporated in the military hat construction of the embodiment of  FIG. 1 . 
         FIG. 9  is a left side view of the embodiment of  FIG. 8 . 
         FIG. 10  is a top view of the embodiment of  FIG. 8 . 
         FIG. 11  is a right side view of the embodiment of  FIG. 8 . 
         FIG. 12  is a bottom view of the embodiment of  FIG. 8 . 
         FIG. 13  is a rear view of the embodiment of  FIG. 8 . 
     
    
    
     Like reference numerals refer to like parts throughout the several views of the drawings. 
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     As represented in the accompanying Figures, the present invention is directed to a military hat construction generally indicated as  10  in  FIG. 1  and comprising a frame generally indicated as  12 . The frame  12  of the military or uniform type hat  10  includes a headband  14 , best shown in  FIG. 1 , that preferably, but not necessarily, has a continuous annular configuration. In addition, the frame  12  includes a visor  16  extending outwardly there from and at least partially defining a frontal portion, generally indicated as  18  of the military hat construction  10 . 
     In addition, and as best shown in  FIG. 1 , but also in  FIGS. 2-7 , the frame  12  includes a stay  20  defining a part of the frame  12  and connected to and extending outwardly or upwardly from the headband  14 . As used herein, the term “upwardly”, “upper”, “lower”, etc. refers to the position of the described structure or component of the hat construction  10  or frame  12 , when worn and/or when in the orientation as appears in  FIG. 1 . 
     Accordingly, the stay  20  is connected to the frame  12  and extends upwardly or outwardly from the headband  14  and visor  16  so as to at least partially define the frontal portion  18  of the military hat construction  10 . In such a frontal position, the stay  20  is also structured to support and position a grommet  22 . The grommet  22  is conventionally used to support and at least partially configure an overlying fabric or other flexible material cover (not shown) disposed in overlying relation to the frame  12 . As is known, the flexible material cover is disposed in covering relation to the grommet  22  as well as the stay  20  and is at least partially supported thereby. Accordingly, the cover at least partially encloses the top/outer periphery and interior portions of the frame  12  of the hat  10 . In addition, the cover will typically include a front portion which overlies substantially the entire front face or surface  34  of the stay  20 , in a manner and position which also at least partially defines the front  18  of the frame  12  of the hat construction  10 , when assembled. As a result, the frontal portion of the cover is clearly observable when viewing the military hat  10  as worn or as disposed in an upright orientation, such as represented in  FIG. 1 . 
     As is perhaps also best illustrated in  FIG. 1 , additional structural features of the stay  20  include the provision of a channel  24  through which at least a portion of the length of the grommet  22  passes, while being supported in its intended position by the stay  20 . With primary reference to the embodiment of  FIGS. 2 through 7 , structural and operative features of the stay  20  include it being preferably formed of a two-ply construction, and further, including a front panel  26  and a rear panel  28 . Both of the panels  26  and  28  are preferably formed of a plastic material having at least a minimal amount of flexibility to accommodate the overall curved configuration of the front  18  of the military cap  10 . However, the plastic material from which the stay  20  is formed also has sufficient rigidity to maintain an upstanding, stable orientation when the hat  10  is fully assembled and the grommet  22  is disposed in supporting and configuring relation to the overlying cover. To this end, the plastic material from which the front and rear panels  26  and  28  are formed may be a polyethylene material facilitating the overlying structuring of the panels  26  and  28  relative to one another. In addition and as represented throughout the indicated Figures, the panels  26  and  28  are substantially equally dimensioned and configured at least in terms of their common, overlying portions. 
     Interconnection of the front and rear panels  26  and  28  is accomplished through the provision of a connecting seam generally indicated as  30 , best shown in  FIG. 2 , and a plurality of other connecting seams  32  disposed in spaced relation to one another and to the primary, peripheral connecting seam  30 . In addition, at least a portion of the remainder of the periphery of the interconnected front and rear panels  26  and  28  may be interconnected to one another by additional peripheral connecting seams  30 ′, wherein the various connecting seams may be formed by heat sealing, sonic welding, etc. As further represented in  FIGS. 3 through 6 , the formed interconnecting seals  30 ,  30 ′,  32 , etc. are sufficient so as to not significantly extend outwardly from the front face or surface  34  of the front panel  26 . Accordingly, one feature of the embodiment of the stay  20 , as represented in  FIGS. 1 through 7 , is the provision of an at least partially smooth or substantially uninterrupted front face or surface  34 . As will be described in greater detail hereinafter, such an uninterrupted surface configuration provides a clean visual appearance of the portion of the cover which overlies the stay  20  and more specifically the front face or surface  34  thereof, when the cover is fully mounted on or attached to the frame  12  in the intended manner. 
     Further with regard to the channel  24 , the upper or outer periphery thereof is at least partially defined by the peripheral connecting seam  30 . The lower or inner boundary may be defined by a plurality of seam segments  33  collectively extending along the lower boundary of the channel  24 . Further, while in one preferred embodiment of the stay  20 , the lower peripheral segments  33  are disposed in spaced relation to one another, they may be replaced by a substantially continuous lower or inner connecting seam  33  similar to the construction of the outer or upper peripheral connecting seam  30 . Accordingly, the outer or upper periphery of the channel  24  coincides with the connecting seam  30 , which in turn defines the upper or outer periphery of the stay  24 . This construction further facilitates the provision of an at least partially smooth and substantially uninterrupted outer surface or face  34  of the front panel  26 . 
     Yet additional features of the stay  20  and more specifically, the channel  24 , include the channel  24  having a substantially closed configuration extending continuously along and adjacent to the upper/outer periphery thereof, which is coincident to the connecting seam  30  thereof. This closed configuration extends continuously between oppositely disposed open ends  40  and  42 . In addition, each of the opposite open ends includes a rear end segment  44  and a front end segment  44 ′. As such, when the grommet  22  is disposed on the interior of the channel  24 , it will be disposed in somewhat overlying, covering relation to the rear end segments  44 . In contrast, the front end segments  44 ′ are disposed in overlying relation to protruding portions of the grommet  22  as it is passed through corresponding open ends  40  and  42 . Therefore, as should be apparent the front end segments  44 ′ of the opposite open ends  40  and  42  are recessed inwardly along the length of the channel  24  substantially towards the center thereof in relation to the outwardly extending rear end segments  44 . 
     This structure serves to further enhance the visually smooth and “clean” or uninterrupted appearance of the front portion of the cover overlying the stay  20 , by virtue of eliminating any projections or protrusions which may normally be disposed at the opposite open ends  40  and  42 . As is recognized, if the front end segments  44 ′ were not recessed inwardly and disposed in overlying relation to outwardly extending portions of the grommet  22 , the front of the hat  10  may include visually apparent creases, projections, etc. 
     With reference now to  FIGS. 8 through 13 , another preferred embodiment of the stay is generally indicated as  120 . It is emphasized, that the intended scope of the present invention includes the military hat  10  and frame  12  incorporating the stay  120  or the stay  20 . Therefore, the additional preferred embodiment of the stay  120  includes preferably a single panel  126  having an outer face or surface  134  and a rear or inner face or surface  136 . The stay  120  also includes a channel  124  formed on the rear face or rear surface  136  of the panel  126 , wherein the channel  124  includes oppositely disposed open ends  140  and  142 . As with the embodiment of the stay as represented in  FIGS. 1 through 7 , the stay  120  may also include the opposite open ends  140  and  142  including a rear end segment  144  and a front end segment  144 ′. As such, the front end segment  144 ′ is recessed inwardly along the length of the channel  124  and towards the center thereof relative to the outwardly extending rear end channel  144 ′. As set forth above, the elimination of any possible projections or protrusion into the cover overlying the stay  120  will be eliminated, at least in part due to the inwardly directed recess of the front end segments  144 ′ of each of the opposite open ends  140  and  142 . 
     Additional features of the channel  124  are its formation exclusively on the inner or rear surface or face  136  of the single panel  126 , and its mounting or connection thereto by oppositely disposed upper and lower connecting seams  130  and  133 . Due to the material and/or structural manufacturing preference, the seams  130  and  133  may be formed continuously between the opposite open ends  140  and  142  by a stitching type connection as should be apparent. As a result the front face or surface  134  of the stay  120  is also provided with an at least partially smooth, substantially uninterrupted surface configuration so as to facilitate a visually smooth or clean, uninterrupted presentation of the front portion  18  of the military hat  10  and more specifically, the portion of the cover which overlies the stay  120 . 
     Additional structural features may be included in the stay  20  of the embodiments of  FIGS. 1 through 7 , or the stay  120 , as represented in the embodiments of  FIGS. 8 through 10 . More specifically, as represented in  FIGS. 2 and 7 , the stay  20  may include a somewhat cut-out portion, generally indicated as  39 . This cut-out portion  39  is disposed, dimensioned and configured to accommodate a reinforcing connector or other reinforcing member. Such reinforcement facilitates the connection and stability of the stay  20  as it is attached to the rest of the frame  12  and defines the upstanding, frontal portion  18 . 
     With regard to the additional preferred embodiment of the stay  120 , a connector as at  141  may be connected to and extend completely through the single panel  126  thereof. As such the connector  141  may serve to facilitate the connection of any symbolic or decorative emblem as it is attached to and viewable from the frontal portion  18  of the military hat  10  when fully assembled. 
     Since many modifications, variations and changes in detail can be made to the described preferred embodiment of the invention, it is intended that all matters in the foregoing description and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. Thus, the scope of the invention should be determined by the appended claims and their legal equivalents. 
     Now that the invention has been described,