Patent ID: 12239179

DETAILED DESCRIPTION

As described above, adjustable headwear may include snapback mechanisms for selecting a desired circumference of a bottom portion of the cap that engages with a wearer's head (e.g., a sweatband region of the cap). However, the available sizes of other snapback headwear are bound by the number of holes that engage with snaps of the snapback mechanism and the spacings between the holes. In this way, a wearer may have to choose between a slightly loose and a slightly tight fit when wearing other snapback headwear.

In order to address the above-described issues and provide an increased granularity to the available sizes of headwear utilizing snapback mechanisms, the present disclosure provides an elastic snapback mechanism. The elastic snapback mechanism described herein enables a wearer to stretch one or both of the tabs used in the snapback mechanism in order to achieve a comfortably snug fit along a sweatband of the headwear.

FIG.1shows a side view of an example headwear, such as a hat or headwear100. As illustrated, headwear100includes a visor102and a crown104. The visor102may be attached to, extend from, and/or otherwise be carried by the crown104(e.g., a bottom portion of the crown104). The crown may comprise a cap configured to extend over a top of a wearer's head. In some embodiments, the crown104may include a plurality of panels extending around a circumference of the crown and intersecting at a central region (e.g., affixed to a button106on the top of the crown). In other embodiments the crown104may be formed of a single panel or piece of fabric (e.g., a unibody construction) forming any suitable hat body shape. In some embodiments, each panel (or the entirety of the crown/visor) may include the same type of fabric or other material. In other embodiments, one or more panels (or the crown) may include a different type of material than the other panels (or the visor).

A headband202may extend around at least a portion of the circumference of the crown104(e.g., along a bottom edge of the crown, away from the button106). The headband202may form another panel of the crown104and/or a junction between the crown and the visor102. The headband may extend around at least a portion of the circumference and/or perimeter of the base of the crown (e.g., leaving an opening206in the back of the crown) and house at least a portion of a sizing mechanism204. For example, headband202may be formed from a substantially rectangular panel that includes terminating ends that are spaced from one another and/or that terminate at tabs of the sizing mechanism204. The size of the hat may be adjusted by pulling the terminating ends closer to one another (or farther apart) using sizing mechanism204, which may also adjust a size and/or shape of the opening206.

FIG.2shows a rear view of headwear100ofFIGS.1and2including a more detailed view of sizing mechanism204. Sizing mechanism204, as illustrated, may form an elastic snapback mechanism. Sizing mechanism204includes two tabs: a first tab208that includes a plurality of holes210, and a second tab212that includes a plurality of protruding snaps214. The snaps214may be sized to engage with holes210in a secure manner. For example, the snaps214may include a top having a larger diameter than a post from which the top extends. The holes210may be formed of a material that is flexible enough to allow the holes to expand and/or stretch slightly to allow passage of the top when the top is inserted into the holes by pressing tabs208and212together, then constrict under the top to hold the snap in place until a force is applied to pull the tab208away from the tab212.

As shown, the tabs208and212may extend into a headband region of the headwear100. For example, the headband202may include material that is folded upward from the crown104to form a pocket between the headband202(e.g., which is configured to come into contact with a wearer) and the outer region of the crown104. In other embodiments, the headband202may be sewn to the crown104to form the above-described pocket. One or more of the tabs208and212may attach to, extend from, and/or otherwise be carried by a) the surface of the headband202that is configured to contact the wearer, b) an interior of the above-described pocket formed between the headband and the outer portion of the crown, and/or c) an exterior of the crown (e.g., away from the headband202and away from the wearer's head. Although illustrated as occupying a substantially central region of the back of the headwear100and/or opening206, the sizing mechanism may be positioned in other locations in some embodiments. For example, tabs208and212may be positioned to a side of the opening or off-centered within the opening when engaged with one another (e.g., when one or more snaps214are positioned within associated holes210).

FIG.2also shows a detailed view of example internal structures and attachment locations for an elastic sizing mechanism of headwear100. As illustrated, tabs208and212may include portions comprising different materials. For example, the portions that engage with one another within the opening206may form a first rigid portion that is formed of substantially rigid or non-elastic material. It is to be understood rigid, as used herein, refers to materials that are less elastic than elements described herein as elastic. For example, a substantially hard plastic may still flex and bend, but may not stretch (e.g., along a perimeter of the headwear100). An elastic portion may include portions of the tabs that attach to the crown104inFIG.2. In contrast to the rigid portions of the tabs, the elastic portions stretch along a perimeter of the headwear100.

As used herein, the term elastic may refer to the elastic characteristic of the material used in the elastic portion. For example, an elastic portion may include any suitable object or material that is able to resume its normal (e.g., unstretched/resting) shape spontaneously after contraction, dilation, or distortion (e.g., stretching). Elastic portions may include any suitable cord, tap, or fabric, which may be woven with strips of rubber or other elastic/elastomeric materials, and/or other material(s)/composite(s) having the features described above that returns to its original length or shape after being stretched. In some examples, elastic portions may include tape made of plastic or other materials that form a flat, smooth, and/or non-rounded strip that may lie flat with the hat and/or follow contours of the hat such that there are no protrusions that may cause discomfort to a wearer.

InFIG.2, the attachment points402aand402bof the elastic portions of tabs208and212, respectively, are substantially equally distant from a center of the opening206. In other words, the attachment points402aand402bmay be equally distant from an edge (404aor404b) of the opening206on an associated side of headwear100, where the sides of the hat are approximately separated from one another along axis406which extends through the center of opening206. In other embodiments, the distance between the attachment points402a/402bof the elastic portions and the center of opening206may be different for each attachment point. In such examples, the rigid portion of the tabs208and212that engage with one another may be off-center with respect to the opening206or the elastic portions of tabs208and212may have different lengths from one another. It is to be understood that attachment or coupling, as used throughout the disclosure, may refer to any suitable coupling mechanism, including but not limited to attaching, stitching, gluing, adhering, chemical bonding, sewing, etc. Particular coupling mechanisms may be performed to provide advantages relating to that coupling mechanism, and disclosure of a particular coupling mechanism to join two or more elements together may be understood to also cover the disclosure of any other suitable coupling mechanism to join those two or more elements together.

The attachment points402aand402bmay include one or more attachment mechanisms. For example, the elastic portions of the tabs may be attached to the crown and/or headband via stitching, gluing, grommets, magnets, and/or any other suitable mechanical or chemical fastening mechanism. Although only one attachment point is shown for each tab208and212, it is to be understood that the elastic and/or rigid portions of the tabs may be attached to the crown and/or headband via two or more attachment points. It is to be further understood that any of the above-described attachment mechanisms may be used in any combination to provide the attachment points for each of the tabs.

As shown at408aand408b, the tabs208and212, respectively, may include a rigid spine. The rigid spine may be another rigid portion of the tabs that is configured to provide structural support for the corresponding elastic portion of that tab. The rigid spines408aand408bmay include a rectangular strip of rigid material having a plurality of protrusions spaced from one another and extending from the rectangular strip toward a bottom and a top of the headwear. The rigid spines408aand408bmay be encased in and/or integrated with a portion of the elastic portion of the respective tabs208and212. For example, the elastic material may be overmolded over the rigid spines such that the elastic material is adjacent to all surfaces of the rigid spines, thereby integrating the rigid spines into the elastic material. The rigid spines may extend from an attachment point of a first rigid portion of the respective tab (e.g., the rigid portion that is exposed and/or configured to engage with the rigid portion of the other tab) to the elastic portion of the respective tab, and may terminate prior to reaching an attachment point of the elastic portion of the respective tab to the crown104and/or headband202. The rigid spines may include one or more holes for increased flexibility and to allow the elastic material to attach to an increased surface area of the rigid material, creating further chemical and mechanical bonds between the two materials. Although each tab is illustrated as including a rigid spine, it is to be understood that in other embodiments, only one tab or neither tab may include a rigid spine.

It is to be understood that the rigid spines may have any suitable arrangement, shape, position, etc. For example, one or more rigid spines may be positioned at any region along the length of the elastic portion of a tab (e.g., closer to an opening in the crown, closer to an attachment point of the tab to the hat/headband, in a center of the tab, etc.) and/or along a height of the elastic portion of the tab (e.g., closer to the top of the tab, closer to the bottom of the tab, at a center of the tab, etc.). If both tabs of the hat include a spine, the spine(s) of one tab may be located in a different region of that tab than the spine(s) of the other tab. In additional or alternative non-limiting examples, a plurality of spines may be distributed next to each other along a length of a tab (e.g., spaced from one another or adjacent to one another with contacting surfaces) and/or distributed above/below each other along a height of the tab (e.g., spaced from one another or adjacent to one another with contacting surfaces). In further additional or alternative non-limiting examples, one or more spines of a hat may have different structural features, such as irregularly spaced/sized protrusions from a center of the spine, dimples or detents in regions of the spine, spikes or jagged edges along the spine, rough and/or smooth material along different regions of the spine, etc. In some non-limiting examples, the material used in the spine may differ in different regions of the spine. The spine may also have different thicknesses in different regions of the structure. As a non-limiting example, protrusions of the spine may be thinner than a center of the spine. It is to be understood that other example configurations of rigid material may be provided to form the spines described herein.

FIG.3shows an isometric view of a bottom of headwear100. As illustrated, attachment point402ais located between an edge of the opening206and an edge502of the visor102(e.g., a location at which the edge of the visor intersects with the crown104). In other examples, the respective elastic portion of each of the tabs may be configured to extend along less than half of the circumference of the perimeter of the crown. For example, the elastic portion of tab208may attach to the crown and/or headband/sweatband along one or more points in attachment region504. In this way, the elastic portion of tab208may extend from the rigid portion of tab208to any location along the perimeter of the crown104between the opening206and the edge502of visor102. In other examples, the attachment region may extend to occupy approximately half of the perimeter of the crown104. It is to be understood that the elastic portion of tab208may extend from the rigid portion of tab208to any location along the perimeter of the crown in some examples, including but not limited to extending all of the way around the perimeter to another rigid portion of a tab on the opposite side of opening206from tab208. The perimeter of the crown may also include multiple sections of material having different properties, each section of material joined to another section of material at different regions along the perimeter. For example, elastic portion of tab208may attach to the crown and/or headband/sweatband along one or more points in attachment region504, and another region of elastic material may extend between two additional points along the perimeter of the crown.

FIGS.4A-4Bshow example elastic snapback sizing mechanisms600aand600b. InFIG.4A, a first tab602aincludes a rigid portion604awith a plurality of holes for engaging with a second tab603a. First tab602aalso includes an elastic portion606a(e.g., an elastic strap) extending from an attachment point608aat which the elastic portion606ais joined to the rigid portion604a. Second tab603aincludes a rigid portion605aand an elastic portion607a, which join at an attachment point609a.

InFIG.4B, tabs602band603binclude two rigid portions each—the first rigid portion604b/605b, which engages with the other first rigid portion of the other respective tab, and second rigid portion606b/607b(e.g., a rigid spine), which does not engage with the other tab. The tabs also include respective elastic portions608b/609b.

FIGS.5and6show an example snapback mechanism700positioned off-centered from a rear of a hat and including a sheathed elastic portion. As illustrated therein, the snapback mechanism700includes a first tab702and a second tab704. The first tab702includes a rigid portion706a, which includes a plurality of holes for engaging snaps of the second tab704. Attached to a terminal end of the rigid portion706ais an elastic portion708. In this example, the elastic portion708comprises an elastic strip (e.g., a rectangular elastic strip of material) sheathed and/or housed within a rigid and/or less elastic material (e.g., fabric). The sheathing material is configured to accommodate the length of the elastic strip when the elastic strip is stretched (e.g., when stretched to a maximum length of the elastic strip). Accordingly, while the elastic strip is not stretched (e.g., to the maximum length), the sheathing material gathers or bunches around the elastic strip.

The second tab704only includes a rigid portion706b, which is attached to an outer surface (e.g., away from a wearer when worn) of the crown710. The rigid portion706bincludes a plurality of snaps configured to be inserted and secured within holes of the rigid portion706aof the first tab702when the sizing mechanism700is in a locked position. As illustrated, the second tab704only occupies a region of the hat on one side of opening712in the crown710, and does not extend within the opening712.

The elastic portion708of the first tab702may be positioned such that it is sandwiched between an outer portion of the crown710of the hat and a headband/sweatband802(shown in more detail inFIG.6). For example, the elastic portion708passes through a pocket formed between the crown710and the headband/sweatband802. For example, the elastic portion708may extend around the perimeter of the crown710to the side of opening712, but may be at least partially obscured by the crown on the outer region of the hat and the headband/sweatband on the inner region of the hat.

FIGS.5and6show the tabs of snapback mechanism700in an example unlatched (e.g., unsecured to one another) configuration.FIG.5shows an unlatched first tab702. In some examples, the elastic portion708includes two terminal ends opposite of one another. A first terminal end902of the elastic portion708is attached to a terminal end of rigid portion706a. In the illustrated example, both the elastic strip within the sheathing material and the sheathing material itself is attached to the terminal end of the rigid portion706a. A second terminal end904of the elastic portion708is attached to the hat between the crown and the headband/sweatband. As illustrated, the second terminal end904is attached a short distance from an edge of opening712of the crown710. However, it is to be understood that the second terminal end904may be attached directly to the edge of the opening712and/or any suitable distance from the edge of the opening712(e.g., extending up to halfway around the perimeter of the crown710and/or between the edge of the opening and an intersection of a visor of the hat and the crown on that side of the hat). It is to be further understood that the attachment point on the elastic portion708may not be positioned at the edge of the second terminal end904. For example, a small amount of the elastic portion708(e.g., less than 5% of the total length of the elastic portion when the elastic is not stretched) may extend past the attachment point of the elastic portion708to the hat. The attachment point may include an attachment to the crown710and/or the headband/sweatband802, and multiple attachment points may be provided in some examples.

FIG.6shows a rear view of unlatched first tab702and an unlatched second tab704. The unlatched second tab704includes two terminal ends opposite of one another. A first terminal end1102includes an outermost snap1103, which may be utilized to provide the largest hat/crown size when the outermost hole1105of the first tab702is secured thereto (e.g., in a latched configuration). In the illustrated example, the first terminal end1102is positioned at an edge of opening712in crown710. A second terminal end1104of the second tab704is positioned at a point along a perimeter of crown710away from opening712. Accordingly, in the illustrated example, the second tab704is positioned on one side of the opening712and does not extend past the opening712. It is to be understood that in other examples, one or both of the terminal ends of a second tab may extend past the edge of the opening712(e.g., toward an opposite side of the opening).

As the second tab704is positioned to the side of the opening712, the second tab704may be attached to the hat (e.g., to the crown710and/or the headband/sweatband802) in multiple locations. For example, both the first and second terminal ends1102and1104may be attached to the crown710. In other examples, the entire length of the second tab704may be attached to the crown (e.g., by stitching, adhesives, and/or other attachment mechanisms that span the length of the tab and/or a circumference/perimeter of the tab). Any suitable number of attachment points and/or portion of the second tab704may be attached to the hat. While the second tab is illustrated as facing an outer surface of the hat (e.g., attached on the outer surface of the crown710), in other examples, the second tab704may be attached to an inner surface of the hat. For example, the second tab704may be rotated such that the snaps extend into an interior of the hat (e.g., opposite of the illustrated direction), and the second tab may be secured to an inner surface (e.g., a wearer-side surface) of the headband/sweatband802. Such an arrangement may enable the snapback mechanism to be hidden on an interior of the hat. As such an arrangement may cause the snapback mechanism to directly contact a wearer's head, a moveable flap of material or other covering mechanism may be added over the mechanism to allow access to the snapback mechanism during adjustment while providing a barrier between the mechanism (e.g., the rigid portions of the mechanism) and the wearer.

FIG.7shows an example snapback mechanism1200including elastic portions disposed in a pocket between a headband/sweatband and an exterior of a crown of a hat.FIG.7shows an interior view of a first tab1202of the example snapback mechanism1200. InFIG.7, a rear view of a rigid portion1204of the first tab1202is illustrated as extending past a terminal end of a headband/sweatband1206and an edge of crown1208. In the illustrated example, the rigid portion1204extends partly between a pocket formed between the crown1208and the headband/sweatband1206.

In an unextended state, an elastic portion of the first tab1202may be housed between the crown1208and the headband/sweatband1206. In the illustrated example, the elastic portion does not extend past an edge of the crown1208. The headband/sweatband1206may be attached to the crown1208along a bottom perimeter of the crown1208so as to create a pocket housing the elastic portion of the first tab1202.

FIG.7also shows an unextended elastic portion of a second tab1402of the example snapback mechanism. The second tab1402includes a rigid portion1304, which extends partly into a pocket formed between the headband/sweatband1206and the crown1208(e.g., at an opposite terminal end of the headband/sweatband than the first tab1202). The second tab1402also includes an elastic portion1306, which is fully housed in the pocket between the headband/sweatband1206and the crown1208in an unextended state. When force is applied to pull the elastic portion1306of the second tab1402, the elastic portion may extend beyond an edge of the crown1208and outside of the pocket formed between the headband/sweatband1206and the crown1208.

The example elastic snapback mechanisms disclosed herein provide an increased granularity to the available sizes of headwear utilizing snapback mechanisms by allowing wearers to stretch the tabs of the snapback mechanism in order to achieve a comfortably snug fit along a sweatband of the headwear. Such modifications of the traditional snapback mechanism preserve the overall ease of use, adjustability, and appearance of that headwear adjustment mechanism while providing the comfort of an elastic headband.

The above examples largely incorporate snapback adjustable sizing mechanisms for hats. However, it is to be understood that the elastic adjustment mechanisms described therein may be applied to any other suitable adjustable sizing mechanism.FIGS.8A-11Cprovide example alternative elastic adjustment mechanisms that may include elastic features as described above and below. In each example, one or more ends of the sizing mechanism may be provided with an elastic overmold, which includes an elastic material overmolded over a rigid or less elastic material (e.g., a material having a lower elasticity than the elastic material). In this way, the elastic material provides for comfort and fine adjustment of the mechanism, while the rigid or less elastic material provides for anchoring, guiding, and/or strengthening the mechanism.

FIGS.8A-8Cshow example pullable tab elastic adjustment mechanisms.FIG.8Ais a rear view of an example headwear, such as a hat1600including a pullable tab elastic adjustment mechanism1602. The mechanism1602may be positioned similarly to the snapback mechanisms described above. For example, although shown substantially centered in the rear of the hat1600, mechanism1602may be attached such that one or more tabs/straps extend toward a side of the hat (e.g., as shown inFIG.6with regards to the snapback mechanism). Mechanism1602may include a fixed strap1604and a pullable strap1606, as well as a loop1608. Fixed strap1604may be substantially fixed (e.g., attached via any suitable mechanism, such as glued, sewn, stapled, stitched, and/or otherwise secured) to the hat1600at a first end (e.g., secured to a headband of the hat) and coupled to the loop1608at a second end opposite the first end. In some examples, the fixed strap1604may be formed as a folded strap, such that one of two terminating ends of the folded strap (the two terminating ends being opposite one another along the longest dimension of the strap) is passed through the loop1608and the two terminating ends are fastened to the headband of the hat (e.g., in an interior of the hat).

Similarly to the fixed strap, the pullable strap1606may have two terminating ends (e.g., opposite one another along the longest dimension of the strap), one of which is substantially fixed (e.g., attached via any suitable mechanism, such as glued, sewn, stapled, stitched, and/or otherwise secured) to the hat on an opposite side of an opening in the crown1614from the attachment point of the fixed strap1604. The other terminating end of the pullable strap1606(e.g., which is not fixed to the hat) may be passed through the loop1608and pulled to adjust a size of the hat. For example, all or a portion of the pullable strap1606may include hook and loop or other removable fastening material to allow one terminating end of the pullable strap to be pulled toward or away from the other terminating end to increase or decrease an overall/effective circumference of the headband. In other examples, the non-fixed terminating end of the pullable strap1606may include a button or other fastener that may be attached to one or more other points on the hat to maintain an adjusted circumference of the headband after pulling the non-fixed terminating end a desired extent. The pullable strap1606may include a tab1610to assist in pulling the non-fixed terminating end of the strap.

FIG.8Bis a detailed view of the adjustment mechanism1602. As illustrated, the adjustment mechanism further includes spines1612aand1612b. The illustrated shape of the spines is exemplary, as any suitable rigid or semi-rigid structure overmolded with an elastic material (e.g., a material more elastic than the spine) may be utilized as the spine. For example, one or both of the straps1604and1606may include an elastic overmold such that elastic material is chemically and mechanically coupled (e.g., bound) to the associated spine. The spines1612aand/or1612bmay provide a rigid structure to assist the associated strap with maintaining a desired shape and provide strength as the straps are adjusted to change a size of the hat. The spines may also guide movement of the straps in the longitudinal direction when pulled in order to prevent twisting of the straps. In some examples, one or both of the straps1604and1606may be attached to respective elastic straps overmolded over respective spines, such that the elastic straps permit additional movement of the one or both straps1604and1606. In such examples, the straps1604and/or1606may be attached to the hat via the additional elastic straps. In other examples, the straps1604and/or1606may be attached directly to the hat and via the additional elastic straps in a reinforced manner.

Although a single spine is illustrated in each of fixed strap1604and pullable strap1606, it is to be understood that one or more spines may be included in one or both of the straps1604and1606. For example, a single spine may be included in fixed strap1604and no spine may be included in pullable strap1606or vice versa. In other examples, one or both straps may include multiple spines. The spines may be positioned in any suitable location and extend for any suitable length to provide the structural support described above. In some examples, spines1612aand1612bmay correspond to rigid spines408aand408bofFIG.2. Accordingly, spines1612aand1612bmay include any one or more of the features of rigid spines408aand408bdescribed above with respect toFIG.2.FIG.8Cshows an isometric view of hat1600. One or both straps may include the same material as the crown of the hat (e.g., as an outer covering; other material, such as a hook and loop material for pullable strap, may be used for an interior region of the strap).

FIGS.9A-9Cshow example hook and loop elastic adjustment mechanisms in accordance with one or more embodiments of the present disclosure.FIG.9Ais a rear view of a hat1700including a hook and loop elastic adjustment mechanism1702. The mechanism1702may be positioned similarly to the snapback mechanisms described above. For example, although shown substantially centered in the rear of the hat1700, mechanism1702may be attached such that one or more tabs/straps extend toward a side of the hat (e.g., as shown inFIG.6with regards to the snapback mechanism). Mechanism1702may include a fixed strap1704and a pullable strap1706. Fixed strap1704may be substantially fixed (e.g., attached via any suitable mechanism, such as glued, sewn, stapled, stitched, and/or otherwise secured) to the hat1700at a first end (e.g., secured to a headband of the hat) and free (in an unfastened condition) or attached to the pullable strap1706(in a fastened condition) at a second end opposite the first end. The pullable strap1706may be arranged similarly to the fixed strap1704(e.g., fixed to the hat at one end and free/fixed to the fixed strap1704at an opposite end), and may include a tab1710to facilitate adjustment of the strap (e.g., pulling it toward the fixed end of the fixed strap1704to tighten the hat). An interior surface of the pullable strap1706may be configured to be in face-sharing contact with an exterior surface of the fixed strap1704to maintain a desired headband circumference (e.g., to change a distance between regions of the headband that terminate at an opening of crown1714of hat1700). Accordingly, the interior surface of the pullable strap and the exterior surface of the fixed strap may include hook and loop material (e.g., one surface including hook material and one surface including loop material). It is to be understood that other fastening mechanisms may be used, such as buttons, adhesive, and/or other suitable fasteners in order to join the surfaces together.

Similarly to the pullable strap adjustment mechanism described above with respect toFIGS.8A-8C, one or both of the straps1704and1706may include elastic material overmolded over rigid or semi-rigid spines1712a/1712b, as illustrated inFIG.9B.FIG.9Cshows an isometric view of hat1700. One or both straps may include the same material as the crown of the hat (e.g., as an outer/inner covering; other material, such as a hook and loop material, may be used for an interior/exterior region of the strap).

FIGS.10A-10Cshow example buckle elastic adjustment mechanisms in accordance with one or more embodiments of the present disclosure.FIG.10Ais a rear view of a hat1800including a buckle elastic adjustment mechanism1802. The mechanism1802may be positioned similarly to the snapback mechanisms described above. For example, although shown substantially centered in the rear of the hat1800, mechanism1802may be attached such that one or more tabs/straps extend toward a side of the hat (e.g., as shown inFIG.6with regards to the snapback mechanism). Mechanism1802may include a fixed strap1804and a pullable strap1806. Fixed strap1804may be substantially fixed (e.g., attached via any suitable mechanism, such as glued, sewn, stapled, stitched, and/or otherwise secured) to the hat1800at a first end (e.g., secured to a headband of the hat) and free (in an unfastened condition) or attached to the pullable strap1806(in a fastened condition) at a second end opposite the first end. The pullable strap1806may be arranged similarly to the fixed strap1804(e.g., fixed to the hat at one end and free/fixed to the fixed strap1804at another part of the strap). Each of the fixed strap1804and the pullable strap1806may include a portion of a buckle1808(e.g., at a terminating end of the fixed strap1804and along the length of the pullable strap1806, respectively). The portions of the buckle on each strap may be configured to connect to one another in a fastened condition, as illustrated inFIG.10A. The portion of the buckle1808included in the pullable strap1806may include a loop through which a terminating end of the pullable strap1806may be passed and pulled to tighten the hat (e.g., to change a circumference of the headband of the hat by changing a distance between regions of the headband that terminate at an opening of crown1814of hat1800).

Similarly to the pullable strap adjustment mechanism described above with respect toFIGS.8A-8C, one or both of the straps1804and1806may include elastic material overmolded over rigid or semi-rigid spines1812a/1812b, as illustrated inFIG.10B.FIG.10Cshows an isometric view of hat1800.

FIGS.11A-11Cshow example ballistic elastic adjustment mechanisms in accordance with one or more embodiments of the present disclosure.FIG.11Ais a rear view of a hat1900including a ballistic elastic adjustment mechanism1902. The mechanism1902may be positioned similarly to the snapback mechanisms described above. For example, although shown substantially centered in the rear of the hat1900, mechanism1902may be attached such that one or more tabs/straps extend toward a side of the hat (e.g., as shown inFIG.6with regards to the snapback mechanism). Mechanism1902may include a fixed loop structure1904and a pullable strap1906. Fixed loop structure1904may be substantially fixed (e.g., attached via any suitable mechanism, such as glued, sewn, stapled, stitched, and/or otherwise secured) to the hat1900to provide a series of loops that may accept a hook1908disposed on the pullable strap1906. The pullable strap1906may be fixed to the hat at one end and free (in an unfastened condition) or fixed (in a fastened condition) to the fixed loop structure1904at another part of the strap. The pullable strap1906may be pulled toward the fixed loop structure1904and the hook inserted into a selected loop of the fixed loop structure to tighten the hat (e.g., to change a circumference of the headband of the hat by changing a distance between regions of the headband that terminate at an opening of crown1914of hat1900).

Similarly to the pullable strap adjustment mechanism described above with respect toFIGS.8A-8C, the pullable strap1906may include elastic material overmolded over one or more rigid or semi-rigid spines1912, as illustrated inFIG.11B.FIG.11Cshows an isometric view of hat1900.

FIGS.12A and12Bshow different views of an example headband2000including an elastic sizing adjustment mechanism2006.FIG.12Ashows an isometric view of the headband2000. The headband2000may include any combination of components and materials to form an adjustable crown-sizing feature of a hat. For example, headband2000may include a sweatband2002, having two terminating ends that are each attached to a respective strap2004(e.g., via a flange, as described in more detail below with respect toFIGS.15-17). The straps2004may be further attached to a sizing mechanism2006. The illustrated example shows a snap-back sizing mechanism, such as that described inFIGS.2-4B, but it is to be understood that any suitable sizing mechanism may be incorporated in the headband2000, including but not limited to those described above with respect toFIGS.8A-11C. Although shown as single elements, it is to be understood that sweatband2002and straps2004may include multiple sections and/or may be formed of composite materials. In some examples, sweatband2002may not extend fully between straps2004, but rather may include two or more sweatband sections that are attached to an interior of a crown of a hat. It is to be understood that headband2000may be incorporated into any suitable hat, including but not limited to those specifically described herein.

As illustrated inFIG.12A, sweatband2002may be attached to strap2004at one or more attachment points2008. The attachment points2008may include any suitable fastening mechanism, including but not limited to those specifically described herein. For example, as described in more detail below, a terminating end of sweatband2002may be inserted into a slot formed between outer and inner surfaces of a terminating end of strap2004and stitching may be passed from the outer surface of the terminating end of the strap, through the sweatband, and through the inner surface of the terminating end of the strap to secure the sweatband in the slot. In other examples, the slot may be lined with glue or other adhesives to secure the sweatband therein. In still other examples, the sweatband may be mechanically secured in the slot (e.g., mechanically clamped, such that protruding features within the slot are pressed through the sweatband).

The straps may be attached at an opposite terminating end (e.g., opposite to the terminating end that is attached to the sweatband) to a rigid structure and/or other feature of sizing mechanism2006. The straps2004may be attached to the sizing mechanism2006in any suitable manner, including but not limited to those described above with respect to attaching the straps to the sweatband. In some examples, the same mechanism may be used to attach the strap to both the sweatband and the sizing mechanism. In other examples, different mechanisms may be used to attach the straps to the sweatband and the sizing mechanism.FIG.12Bshows a front view of headband2000, including attachment points2010at which the straps2004are attached to the sizing mechanism2006.

FIG.13shows an example view of overmolding within an example headband2100of a hat. For example, spine structures2102and2104, which may be formed similarly to rigid spines408aand408bofFIG.2, may extend from tabs of a sizing mechanism2106and attachment points2108, respectively. Straps2110may include elastomeric material overmolded over the spine structures2102and2104to form an elastic copolymer overmold.

Attachment points2108may connect the sizing mechanism2106(e.g., via straps2110) to a region of a hat (e.g., a sweatband of a hat or other material in a perimeter portion of a crown of the hat), which may be formed of any suitable material. As discussed above with respect to rigid spines408aand408b, the overmolding may promote structural integrity near points of attachment to control a direction of elastic stretching and retain a shape of the headband.

FIG.14shows an example detail view of overmolding within an example elastic member2200. Elastic member2200may include an elastomeric strap2202including one or more spine structures2204aand optionally2204bextending from attachment points2206. As shown by the dashed lines, spine structure2204bis optional and may be omitted in examples where only one end of the elastic member2200is to be reinforced. For example, the terminating end at attachment points2206of the elastic member that is closest to spine structure2204may be attached to a sizing mechanism, while the other terminating end at attachment point2206may be attached to a sweatband of a hat or may extend continuously around a perimeter of the hat in order to allow the elastic member2200itself to serve as the sweatband of the hat. In this example, spine structure2204bmay not be included, and the elastic member2200may only include one spine structure. In other examples, where reinforcement at both terminating ends is used, the elastic member2200may include both spine structures2204aand2204bnear opposing terminating ends of the elastic member. In still other examples, one or more spine structures may be disposed at any suitable location(s) along the length of the elastic member2200. The above-described elements of elastic member2200may be similar to the likewise-named elements of headband2100, and the above-description of such elements may thereby apply to elastomeric strap2202, spine structures2204, and attachment points2206. As illustrated inFIG.14, in some examples, strap2202may extend from one attachment point to another, without including a specific sizing mechanism there between. Strap2202may enable any two structures to be attached to one another via an elastic intermediary element by attaching to the two structures at respective attachment points2206. Accordingly, elastic member2200may be coupled to a sizing mechanism at one terminating end (e.g., via one attachment point2206) and a headband or other hat feature at an opposite terminating end (e.g., via the other attachment point2206). In another example, two sections of a headband may be attached to one another via the elastic member2200. The above examples are non-limiting, and any two elements may be joined via elastic member2200to allow the two elements to be elastically coupled to one another.

FIG.15shows a front isometric view of an example band2300including a double-sided sew flange for an elastic sizing mechanism or other suitable structure having multiple elements that are to be joined together. Band2300may include a first band section2302joined to a second band section2304via a double-sided sew flange2306. The first and second band sections2302and2304may include any suitable material or combination of materials. In one example, band section2302may include a terminating end of a sizing mechanism, which may be rigid or semi-rigid in some examples, and band section2304may include a terminating end of a headband of a hat. Flange2306includes a pair of slots2308with a buffer element2310disposed there between. A terminating end of each of the band sections2302and2304may be inserted into a respective slot2308(e.g., to a maximum depth that corresponds to contacting the buffer2310).

Stitching2312and/or any other suitable securing/fastening mechanism may be utilized to secure/fasten the band sections within the respective slots. For example, the stitching may pass through holes2314and through the band sections to secure the band sections within the slot. In other examples, holes2314may represent a secondary securing mechanism (e.g., bolts/tacks or similar structures may be passed through the holes and the band sections to the other side of the flange). The holes2314may additionally or alternatively serve as indicators to guide insertion of stitches and/or other fastening mechanisms. In some examples, the flange2306may be at least semi-rigid to provide structural support for the band sections. In such examples, the flange2306may also be semi-flexible to promote comfort (e.g., when the flange is used to join material in a garment, such as a headband of a hat) and durability (e.g., to allow some give while the band sections move relative to one another).

FIG.16shows an example detail view of a long double-sided sew flange2400for an elastic sizing mechanism or other suitable structure having multiple elements that are to be joined together. As illustrated, flange2400may include two terminating ends2402that include slots2404formed within an opening between a front surface2406and a rear surface2408of the flange2400. As described above with respect toFIGS.12A-15, two pieces of material that are to be joined may each be inserted into respective slots. In some examples, stitching, clamping, or other fastening mechanisms may be used to secure the material within the slots. Additionally or alternatively, the material may be secured within the slots due to a texture pattern of an interior of the slots and/or adhesive material disposed within and/or around the slots. The slots may form an “H” bracket or coupler and may include indicators for guiding application of stitching, clamping, or other fastening mechanisms.

FIG.17shows an example headband2500of a hat including a double-sided sew flange2502coupling a first material2504to a second material2506. As described above, the two joined materials2504and2506may comprise any suitable material, and may include material of a sizing mechanism and a headband, respectively, in some examples. Detail A ofFIG.17shows a close-up view of a slot2508of flange2502. As shown, a terminating end of each of the front surface2510and rear surface2512of the flange2502may be rounded in order to provide a gradual transition between the flange and the material2506. As shown, there may be a gap between the material2506and one or more regions of the interior of the slot. The gap may be filled with an adhesive and/or mechanically closed over the material by way of stitching, clamping, etc. In other examples, the gap (e.g., a gap between the two sections of material2504and2506) may be maintained to allow additional stretching/movement during use. The size of the slot (e.g., the width, height, thickness, etc.) may be based on the material being inserted therein and/or may be a function of the overall width/height/thickness of the flange. Example dimensions of the flange may include ¾″ high (e.g., from a bottom to a top), 1-1.5″ wide (e.g., between terminating ends and/or between slot openings), with a slot opening that measures 25/1000″ between interiors of the front and rear surfaces of the terminating ends of the flange. It is to be understood that these measurements are exemplary in nature, and any suitable dimensions may be utilized. The flange may be made of any suitable material, including but not limited to polypropylene, nylon, polyethylene, and/or other soft-durable material.

In some examples, the flange may be a part of a kit or assembly for adapting a hat with an elastic sizing mechanism. For example, the kit or assembly may include the flange and one or both materials inserted therein. The material(s) may be attached to existing features of the hat to adapt the hat. For example, the material(s) may include a sizing mechanism and/or an elastomeric strap. Attaching these materials to one another and the hat via the flange enables the hat to be easily adapted to include an elastic sizing mechanism. In some examples, the flange itself may be formed of elastomeric material. In such examples, the flange may be attached to a rigid portion of a sizing mechanism via one slot and to a headband of a hat via another slot, the flange providing additional flexibility when using the sizing mechanism.

The disclosure above also provides for headwear including a crown including a cap, and a size-adjusting mechanism extending around a portion of a perimeter of the cap and adapted to selectively adjust a size of the cap, the size-adjusting mechanism comprising a first tab including a plurality of holes, and a second tab including a plurality of snaps configured to engage with the plurality of holes of the first tab, at least one of the first tab and the second tab being coupled to the perimeter of the cap via an elastic portion attached to a terminal end of a rigid portion of that tab. In a first example of the headwear, the headwear may include a visor extending from the cap and a headband extending around a portion of the perimeter of an interior of the cap and including terminating ends that are spaced from one another at an opening in a rear of the cap. A second example of the headwear optionally includes the first example, and further includes the headwear wherein the elastic portion of the first tab and/or the second tab is attached between the headband and the crown and wherein at least a portion of the elastic portion that is attached between the headband and the crown extends within a pocket formed between the headband and the crown. A third example of the headwear optionally includes one or more of the first and the second examples, and further includes the headwear wherein the elastic portion of the first tab and/or the second tab comprises an elastic strap extending from the terminal end of that tab to an attachment point on the perimeter of the cap, the attachment point for the elastic strap being positioned between an edge of the visor and an edge of the opening in the rear of the cap, the edge of the opening in the rear of the cap being on the same side of the cap as the edge of the visor. A fourth example of the headwear optionally includes one or more of the first through the third examples, and further includes the headwear wherein each of the first tab and the second tab is coupled to the perimeter of the cap via a respective elastic portion attached to a terminal end of the rigid portion of that tab. A fifth example of the headwear optionally includes one or more of the first through the fourth examples, and further includes the headwear wherein the respective elastic portion of each of the first tab and the second tab is configured to extend along less than half of the circumference of the perimeter of the crown. A sixth example of the headwear optionally includes one or more of the first through the fifth examples, and further includes the headwear wherein a distance between the attachment point for the elastic strap of the first tab and a first edge of the opening in the rear of the cap is substantially equal to a distance between the attachment point for the elastic strap of the second tab and a second edge of the opening, the second edge of the opening being opposite from the first edge of the opening respective to a center of the opening. A seventh example of the headwear optionally includes one or more of the first through the sixth examples, and further includes the headwear wherein a distance between the attachment point for the elastic strap of the first tab and a first edge of the opening in the rear of the cap is different than a distance between the attachment point for the elastic strap of the second tab and a second edge of the opening, the second edge of the opening being opposite from the first edge of the opening respective to a center of the opening. An eighth example of the headwear optionally includes one or more of the first through the seventh examples, and further includes the headwear wherein the elastic portion of the first tab and/or the second tab is attached to a respective edge of the opening at an opposite end of the elastic portion than the rigid portion of that tab. A ninth example of the headwear optionally includes one or more of the first through the eighth examples, and further includes the headwear wherein the elastic portion of the first tab and/or the second tab is attached at two or more positions between an edge of the opening and an edge of the visor, the edge of the opening and the edge of the visor being on the same side of the headwear. A tenth example of the headwear optionally includes one or more of the first through the ninth examples, and further includes the headwear wherein the rigid portion of the first tab and/or the second tab is attached to one or more of the headband and the crown. An eleventh example of the headwear optionally includes one or more of the first through the tenth examples, and further includes the headwear wherein the elastic portion comprises an elastic strap encased in fabric and attached to at least one of the first tab and the second tab. A twelfth example of the headwear optionally includes one or more of the first through the eleventh examples, and further includes the headwear wherein the rigid portion of the first tab and/or the second tab comprises a first rigid portion, the first tab and/or the second tab further comprising a rigid spine encased in a portion of the elastic portion of the first tab and/or the second tab. A thirteenth example of the headwear optionally includes one or more of the first through the twelfth examples, and further includes the headwear wherein the rigid spine comprises a rectangular strip of rigid material having a plurality of protrusions spaced from one another and extending from the rectangular strip toward a bottom and a top of the headwear. A fourteenth example of the headwear optionally includes one or more of the first through the thirteenth examples, and further includes the headwear wherein the rigid spine extends from an attachment point of the first rigid portion of the first tab and/or the second tab to the elastic portion of the first tab and/or the second tab, and terminates prior to reaching an attachment point of the elastic portion of the first tab and/or the second tab to the cap.

The disclosure also provides for headwear including a crown including a cap, and a size-adjusting mechanism extending around only a portion of a perimeter of the cap and adapted to selectively adjust a size of the cap, the size-adjusting mechanism comprising a first tab including a plurality of holes, and a second tab including a plurality of snaps configured to engage with the plurality of holes of the first tab, each of the first tab and the second tab being coupled to the perimeter of the cap via an elastic portion attached to a terminal end of a rigid portion of that tab. A first example provides for the headwear wherein the elastic portion of the first tab and the second tab is configured to be more elastic in a direction extending along the perimeter of the cap than a direction extending from a bottom of the cap to a top of the cap.

The disclosure also provides for headwear including a crown including a cap; and a size-adjusting mechanism extending around only a portion of a perimeter of the cap and adapted to selectively adjust a size of the cap, the size-adjusting mechanism comprising one or more straps, at least one of the one or more straps being coupled to the perimeter of the cap via an elastic portion attached to a terminal end of a rigid portion of that strap or via an elastic portion integrated in that strap, the elastic portion comprising elastic material overmolded onto a rigid structure.

The disclosure also provides for a kit for elasticizing a sizing mechanism for headwear, the kit including a double-sided sew flange, the double-sided sew flange having two terminating ends opposite one another, each terminating end including a slot for inserting material, and a size-adjusting mechanism adapted to selectively adjust a size of the cap, the size-adjusting mechanism being coupled to a first terminating end of the two terminating ends of the double-sided sew flange via the slot of the first terminating end, at least one of the double-sided sew flange and the size-adjusting mechanism comprising elastomeric material. A first example of the kit optionally includes the kit wherein a second terminating end of the two terminating ends is coupled to a headband of the headwear. A second example of the kit optionally includes the first example and further includes the kit wherein the double-sided sew flange comprises an elastic copolymer overmold, the elastic copolymer overmold comprising elastic material overmolded onto a rigid structure. A third example of the kit optionally includes one or more of the first and the second examples and further includes an elastomeric strap coupled to or extending from the size-adjusting mechanism, wherein the size-adjusting mechanism is coupled to the first terminating end of the double-sided sew flange indirectly via the elastic strap, the elastic strap being attached to one of the two terminating ends of the double-sided sew flange.

FIGS.18-21show an example ballistic sizing mechanism. In some examples, the ballistic or bombardier sizing system may include webbing for sewn sizing loops on a side of the crown to provide a custom fit. The sizing system may be created with super tough woven webbing, metal retention clips that create a positive connection with sewn loops, and high quality elastic to ensure performance in any situation. An elastic webbing anchor may be used to allow a wearer to customize fit beyond pre-sized webbing loops. An absence of moving parts removes the possibility of breaking the sizing mechanism in the field.

Headwear3100may include a cap with a brim extending from or otherwise carried by a hat body3104(e.g., a crown). A headband3108may form another panel of the hat body and/or a junction between the hat body and the brim. For example, as shown inFIG.18, the hat body may extend upward from the headband3108to form a crown that is configured to cover a head of a wearer of headwear3100. Headband3108may extend around the circumference of the base of the hat body and house the sizing mechanism3110. In some embodiments, the headband3108may extend around the entire circumference of the hat body (e.g., formed from a single, continuous loop of material) and/or may extend partly around the circumference (e.g., leaving an opening in the back of the hat body). For example, headband3108may be formed from a substantially rectangular panel that includes terminating ends that are spaced from one another. The size of the hat may be adjusted by pulling the terminating ends closer to one another (or farther apart) using sizing mechanism3110.

Sizing mechanism3110may be provided to enable the headwear to be size adjustable and conform to a variety of head sizes and types. As illustrated, sizing mechanism3110includes a strap3502(e.g., a pullable strap) extending from an inner region of the cap to an outer region of the cap along a circumference of the hat body when disposed in a locked position. For example, strap3502may be housed and secured to the cap within a pocket formed in headband3108(e.g., sandwiched between at least two layers of material) at a first end and attached to a sizing clip3504(e.g., that forms a hook) at a second end, opposite from the first end. In this way, the strap3502may extend out of an opening in the headband3108. In other embodiments, the strap may be attached to an interior of the cap (e.g., exposed to a wearer when placed on the head of the wearer and not within a pocket of material) or an exterior of the cap at the first end. Strap3502may include and/or be composed of flexible material, such as an elastic polymer, in order to provide a resilient tightening mechanism. In one example, strap3502may include sizing tape including webbing with elastic extension (e.g., ¾″ elastic).

A guiding loop3506may be attached to an outer region of the cap near a fixed loop structure comprising a plurality of looped fasteners508, also secured to the outer region of the cap. Guiding loop3506may be formed of flexible material (e.g., material that is more flexible than the material of strap3502and/or looped fasteners3508) that may stretch to allow the passage of the sizing clip3504when the strap is directed through the guiding loop toward the looped fasteners. The guiding loop3506may also provide an anchor to which the sizing clip may be attached for additional size customization, as illustrated inFIG.21. The looped fasteners may be made of the same material as strap3502or of a different material (e.g., with a different amount of flexibility). For example, the looped fasteners may be formed by attaching a strip of material to a headband of the cap (e.g., sewing vertical stitching) in multiple locations along the strip while the strip is allowed to loosely gather between attachments. The plurality of looped fasteners may be secured to the headband between a bottom circumferential edge of the headband and a top edge of the headband. Further, the plurality of looped fasteners may be attached to the headband at a position spaced apart from the opening from which the strap extends. For example, as shown inFIG.18, the opening from which the strap extends may be positioned on a first side of the opening of the headband and the looped fasteners may be positioned on a second side of the opening of the headband, such that the strap extends across the opening of the headband. The looped fasteners may be any suitable size relative to the sizing clip3504. In some embodiments, each of the looped fasteners may be a same size (e.g., have a same opening area when not stretched and/or have a same width/height). In other embodiments, one or more looped fasteners may be sized differently from one or more other looped fasteners. Although illustrated along a right side of the headwear, it is to be understood that the looped fasteners and other sizing mechanism elements may be located in any suitable region of the cap. For example, the sizing mechanism may be mirror-reversed or have a shifted location from the illustrated example and still fall within the scope of this disclosure.

The sizing clip3504may be formed of any suitable material. For example, sizing clip3504may be formed of metal or a metal alloy for strength, plastic for weight reduction, and/or any suitable combination of materials. The sizing clip may include a first closed loop that is attached to an associated loop of material from the strap3502and a second, partially open loop configured to be removably attached to a selected looped fastener (e.g., a selected loop)3508. The partially open loop may include two substantially parallel prongs (e.g., an innermost prong3802ofFIG.21forming a side of the first closed loop and an outermost prong3804ofFIG.21spaced from the first closed loop) attached at one end and opened at another such that one of the prongs may pass through a looped fastener. As described above, one of the prongs may be configured to attach to guiding loop3506in order to provide additional width beyond that supplied by the looped fasteners.

In some embodiments, a hook3806(illustrated inFIG.21) along the outermost prong3804may be provided that is configured to wrap around a lower edge of a selected looped fastener or guiding loop for further securing the sizing clip to the fastener/loop. In other embodiments, the hook may be absent in order to enable the sizing clip to pass through a looped fastener more easily. In some embodiments, a latch or other securing mechanism, represented by dashed line3808ofFIG.21, may be included on the hook to provide an additional locking mechanism for locking the hook onto a particular looped fastener or onto the guiding loop3506. In additional or alternative embodiments, one or more additional sizing hooks may be including in the sizing mechanism. For example, utilizing a plurality of sizing hooks may enable the snapback force of the elastic strap to be divided across each hook, reducing the overall force on each hook and reducing the possibility that all of the hooks will be pulled from out of the respective loops.

In some embodiments, the opening of the looped material for each looped fastener may be sized to be close to a width of the widest point of the prong of the sizing clip. For example, the loop of the fastener may be sized such that the loop of the fastener stretches during insertion of the prong and snap back to a tight fit once the prong is in a locked position inside of the looped fastener. Any suitable number of looped fasteners may be provided. A shock cord elastic sizing tape retention loop may be utilized for the looped fasteners and/or the guiding loop.

The description of embodiments has been presented for purposes of illustration and description. Suitable modifications and variations to the embodiments may be performed in light of the above description. The described example headwear are exemplary in nature, and may include additional elements and/or omit elements. The subject matter of the present disclosure includes all novel and non-obvious combinations and sub-combinations of the various structures and configurations, and other features, functions, and/or properties disclosed.

As used in this application, an element or step recited in the singular and proceeded with the word “a” or “an” should be understood as not excluding plural of said elements or steps, unless such exclusion is stated. Furthermore, references to “one embodiment” or “one example” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. The terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements or a particular positional order on their objects. The following claims particularly point out subject matter from the above disclosure that is regarded as novel and non-obvious.