HATS, HAT INSERTS, AND RELATED METHODS

Abstract

A hat insert for maintaining a structure of a hat and a characteristic of a head of a wearer, and related methods of manufacture and use. The hat insert is constructed by attaching a shaper configured for supporting the hat to a liner configured for contacting the wearer's hair or scalp. An improved hat is constructed by inserting the hat insert into the hat. When the improved hat is worn by the wearer, the hat insert supports the hat and protects it from damage and also engages the wearer's hair or scalp and protects hair strands, hair follicles, and skin pores from becoming damaged or soiled as a result of wearing the hat.

Description

FIELD

The disclosure relates to an improved hat insert for maintaining a structure of a hat and a characteristic of a scalp of a wearer during use. The hat insert is constructed and inserted into the hat and maintains a shape of the hat as the wearer wears the hat with the hat insert therein. The hat insert includes materials and design features that prevent damage to the scalp, including the skin and the hair of the wearer.

BACKGROUND

Many individuals wear head coverings, such as hats, as protection from and to increase visibility when outdoors in sunlight, cold temperatures, and precipitation such as rain or snow. Other types of head coverings, such as helmets, provide physical protection from impacts. While such head coverings are beneficial for a variety of reasons, they may also cause problems for many wearers, such as damage to or soiling of hair strands, hair follicles, skin pores, sweat glands, and other anatomical features of the wearer, typically as a result of the head covering being worn too tightly against the scalp, or an interior of the head covering being comprised of materials which are abrasive against the wearer's skin or hair. In addition, the head covering may become damaged or worn with use, either gradually or acutely, which can decrease the effectiveness or appearance of the head covering and result in increased costs associated with repairing or replacing the head covering. In addition, an individual may wear many hats or head coverings, and the different hats or head coverings worn may not provide a consistent degree of protection for the wearer's hair or skin.

Accordingly, there is a need for a modular hat insert for protecting a hat or other head covering as well as the hair and skin of the wearer during use. The present invention addresses this unmet need.

SUMMARY

In one aspect, the disclosure provides a hat insert that can be inserted into a head covering, such as a hat, to produce an improved head covering that can be worn by a wearer to protect the scalp, hair, and skin, as well as the structural integrity of the head covering, during use. The hat insert comprises a shaper associated with a liner. The shaper is configured to support the hat, and the liner is configured to contact a head of a wearer when an improved hat that comprises the hat insert and the hat is worn by the wearer.

The shaper may be attached to an exterior or an interior of the liner, and in implementations, the liner may comprise an outer liner and an inner liner to form an inner space which holds or is secured to the liner. The liner may include a crown support that engages and supports a crown of the hat when the hat insert is within an interior of the hat. One or more friction tabs may be disposed at an interface between the hat insert and the interior of the hat to prevent the hat insert from moving or slipping relative to the hat during use. The shaper may be easily deformable to adhere to the shape of the wearer's head or the shape of the hat and may include a material that deforms with application of a compressive force and reforms with removal of the compressive force, such as a foam material. The liner may include at least a portion thereof that is moisture-absorbing so that sweat secreted by the wearer is absorbed and does not soil the hat or the rest of the liner.

In implementations, the shaper comprises a lower portion that is removably insertable into a sweatband of the hat and an upper portion that is removably engageable with the interior of the hat, and in such implementations, the lower portion may be delineated from the upper portion by a centerline of the shaper that aligns with a waistband entry of the hat when the lower portion of the shaper is inserted into the waistband. The lower portion comprises a plurality of lower protrusions separated by lower notches that prevent bulge and facilitate alignment of the shaper to the hat, and the upper portion comprises a plurality of upper protrusions separated by upper notches that prevent bulge and support a sidewall of the hat.

In implementations, the shaper may be malleable to conform with and maintain a shape of the hat. The shaper may include a malleable skeleton therein that comprises a primary member with a plurality of secondary members that extend therefrom. The primary member may extend along a horizontal length of the shaper and the secondary members may extend vertically along lengths of the plurality of lower protrusions and the plurality of upper protrusions to provide additional support.

In implementations, the liner may include a soft material that engages the wearer's hair or scalp and protects hair strands, hair follicles, and skin pores of the wearer from becoming damaged or soiled as a result of wearing the improved hat. The soft material may comprise silk, satin, nylon, or any combination thereof, or another suitable material according to a particular implementation.

In implementations, the hat is a billed cap, such as a baseball hat, with a hat aperture at a posterior portion thereof, and the liner includes a liner aperture positioned at a posterior portion thereof that is configured to align with the hat aperture. The liner aperture may be defined by a liner fastener configured to secure the liner at a diameter suitable for fitting the head of the wearer.

In another aspect, the disclosure provides an improved head covering, such as an improved hat, that comprises a hat with a hat insert of the disclosure removably attached to an interior of the hat. The improved hat may be disassembled (e.g., hat physically separated from hat insert) or assembled (e.g., hat with hat insert therein). The hat may be provided separately from the hat insert or may be provided together with the hat insert as a kit. When the hat and the hat insert are provided as a kit, other items may also be provided in the kit.

In yet another aspect, the disclosure provides a method for producing a hat insert, the method comprising: constructing a shaper, constructing a liner, and associating the shaper with the liner. The shaper may be constructed by surrounding a malleable skeleton with a material, such as a material that deforms with application of a compressive force and reforms with removal of the compressive force, such as a foam material. The malleable skeleton may comprise a primary member with a plurality of secondary members that extend therefrom. The liner may be constructed by cutting or sewing one, two, or more than two soft materials configured to engage the wearer's hair or scalp and protect hair strands, hair follicles, and skin pores of the wearer from becoming damaged or soiled as a result of wearing an improved hat; exemplary soft materials include silk, satin, nylon, and the like. The shaper may be attached to the liner by sewing, adhesive, and the like, whether in an interior space of the liner or on an exterior surface of the liner. Friction tabs may be attached to the exterior of the liner such that they are disposed at an interface between the hat insert and the interior of a hat to prevent the hat insert from moving or slipping relative to the hat during use.

In yet another aspect, the disclosure provides a method for assembling an improved hat that comprises the hat insert inserted therein, the method comprising inserting the hat insert into a hat. The hat insert may be inserted into the hat by slipping a lower portion of the shaper of the hat insert into a sweatband of the hat such that an upper portion of the shaper engages with a sidewall of the hat. The hat insert may be secured in place by friction tabs of the hat insert which prevent movement of the hat insert relative to the hat when the improved hat is worn. If the hat insert is needed for use with a different hat, the hat insert may be removed from the hat by pulling the lower portion of the shaper out from the sweatband of the hat and disassociating friction tabs, when present. Once removed from the hat, the hat insert may be cleaned or inserted into the different hat for further use.

The invention generally relates to improved hats and hat inserts which may be manufactured with appropriate materials and processes, and which may be scaled as needed.

Other objects, features, and advantages of the invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Although the characteristic features of the invention will be particularly pointed out in the claims, the invention itself and manners in which it may be made and used may be better understood after a review of the following description, taken in connection with the accompanying drawings, wherein like numeral annotations are provided throughout.

FIG. 1A depicts a perspective view of assembly of an exemplary improved hat by inserting an exemplary hat insert of the disclosure into an exemplary hat.

FIG. 1B depicts a perspective view of the improved hat after assembly.

FIG. 2 depicts a front view of assembly of an exemplary shaper.

FIG. 3A depicts a top view of assembly of the exemplary hat insert by associating the exemplary shaper with an exemplary liner.

FIG. 3B depicts a top view of the exemplary hat insert after assembly.

DETAILED DESCRIPTION OF THE INVENTION

Reference is made herein to the attached drawings. Like reference numerals may be used in the drawings to indicate like or similar elements of the description. The figures are intended for representative purposes and should not be considered limiting.

[23] Illustrative embodiments of the disclosure will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the disclosure are shown. The disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements.

Whenever appropriate, terms used in the singular also will include the plural and vice versa. The use of “a” herein means “one or more” unless stated otherwise or where the use of “one or more” is clearly inappropriate. The use of “or” means “and/or” unless stated otherwise. The use of “comprise,” “comprises,” “comprising,” “include,” “includes,” and “including” are interchangeable and not intended to be limiting. The term “such as” also is not intended to be limiting. For example, the term “including” shall mean “including, but not limited to.”

The following description is provided as an enabling teaching of the disclosed articles, systems, and methods in their best, currently known embodiments. To this end, those skilled in the relevant art will recognize and appreciate that many changes can be made to the various aspects of the articles, systems, and methods described herein, while still obtaining the beneficial results of the disclosure. It will also be apparent that some of the desired benefits of the present disclosure can be obtained by selecting some of the features of the present disclosure without utilizing other features. Accordingly, those who work in the art will recognize that many modifications and adaptations to the present disclosure are possible and can even be desirable in certain circumstances and are a part of the present disclosure. Thus, the following description is provided as illustrative of the principles of the present disclosure and not in limitation thereof.

As used throughout, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a gasket” can include two or more such gaskets unless the context indicates otherwise.

As used throughout, “substantially” with respect to a measure can refer to a range of values comprising +/−10 degrees. For example, substantially orthogonal, normal, or parallel can include embodiments, where the referenced components are oriented +/−10 degrees of being classified as orthogonal, normal, or parallel respectively.

Ranges can be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

As used herein, the terms “optional” or “optionally” mean that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.

The word “or” as used herein means any one member of a particular list and also includes any combination of members of that list.

In the description and the claims, the terms “hat,” “head covering,” “helmet,” and the like, are intended to be interchangeable and non-exclusive unless otherwise stated. These and similar terms do not exclude any wearable head article that is not disclosed herein, and are intended to encompass any such item, including but not limited to a device, a system, an article, an object, and the like, that may be worn for any purpose by placement of the item on or around the head of an individual.

Referring now to FIGS. 1A and 1B, there are depicted a perspective view of assembly of an exemplary improved hat by inserting an exemplary hat insert of the disclosure into an exemplary hat (FIG. 1A) and a perspective view of the improved hat after assembly (FIG. 1B). The disclosure provides a hat insert 104 that can be inserted into a head covering, such as a hat 102, to produce an improved head covering 100 that can be worn by a wearer to protect the scalp, hair, and skin, as well as the structural integrity of the head covering 100, during use. The hat insert 104 comprises a shaper 106 associated with a liner 108. The shaper 106 is configured to support the hat 102 so that the hat 102 does not collapse or deform and may be of a sufficient length to conform with a circumference of an interior cavity of the hat 102, and the liner 108 is configured to contact a head of a wearer when an improved hat 100 that comprises the hat insert 104 and the hat 102 is worn by the wearer.

In the shown embodiment, the shaper 106 (shown in broken lines) is attached to an interior of the liner 108, but in embodiments, the shaper 106 may be attached to an exterior of the liner 108 or may be placed within or secured to an inner space of the liner 108 as may be formed by an outer liner and an inner liner that are connected together. The shaper 106 includes an upper portion 112 and a lower portion 114 which are delineated by a centerline 121 of the shaper 106. The lower portion 114 comprises a plurality of lower protrusions separated by lower notches 120 that prevent bulge and facilitate alignment of the shaper 106 to the hat 102, and the upper portion 112 comprises a plurality of upper protrusions 116 separated by upper notches that prevent bulge and support the sidewall 123 of the hat 102. When the shaper 106 is inserted into the hat 108, the lower portion 114 of the shaper 106 is inserted into a sweatband 103 of the hat 108 and the centerline 121 of the shaper 106 aligns or substantially aligns with an entry 122 of the sweatband 103. While the exact design of the sweatband 103 may vary, in certain instances, the sweatband 103 of the hat 102 may circumscribe the interior surface of the hat 102. In various configurations, the lower portion 114 of the shaper 106 extends downward into the sweatband 103 and the upper portion 112 of the shaper extends upward and engages sidewalls 123 of the hat 102 and provides support thereto for maintaining the structural integrity of the hat 102.

In the shown embodiment, the hat insert 104 includes a crown support 124, located in an upper region of the hat insert 104. The crown support 124 may be configured to aid the hat insert 104 to define a shape that is consistent with an inner surface of the hat 102. The crown support 124 may include a metal wire component, a plastic component, and the like, or any such similar rigid or semi-rigid structure for supporting a crown 125 of the hat 102. In a further aspect, the crown support may comprise an arrangement of stitching between pieces or portions of the liner 108. Regardless of a particular implementation, the crown support 124 circumscribes the upper region of the hat insert 104 and thereby engages and supports the crown 125 of the hat 102 when the hat insert 104 is within the interior of the hat 102.

In implementations, one or more friction tabs 122 may be disposed at an interface between the hat insert 104 and the interior of the hat 102, as part of the improved hat 100, to prevent the hat insert 104 from moving or slipping relative to the hat 102 during use of the improved hat 100. The friction tabs may be engagement points between the cover insert 104 and the interior surface of the hat 102. The friction tabs 122 may be placed on either or both of the shaper 106 and the liner 108, although in the shown embodiment, are placed on the liner 108 for purposes of demonstration. The friction tabs 122 may include padding that has a non-slip surface or character and may provide additional stability to the cover insert 104 by reducing movement of the cover insert 104 when the cover insert 104 is engaged to the interior surface of the hat 102. The friction tab 122 may include any suitable non-slip material or non-slip pattern, or both. The friction tab 122 may be adhered to or stitched to the liner 108. The non-slip material may comprise a silicone or a rubber material, and the non-slip pattern may comprise a particular texture or graining along a surface of the friction tab 122 that engages the interior surface of the hat 102.

In implementations, the shaper 106 may be easily deformable to adhere to the shape of the wearer's head or the shape of the hat 102, and may include a material that deforms with application of a compressive force and reforms with removal of the compressive force, such as a foam material. In this manner, the deformable character of the shaper 106 may increase or maintain comfort or tolerability of the improved hat. In implementations, the liner 108 may include at least a portion of a moisture-absorbing or moisture-wicking material, such that sweat secreted by the wearer is absorbed and does not soil the hat 102 or other portions of the liner 108.

A method for assembling the improved hat 100 comprises inserting the hat insert 104 into the hat 102, for example, by slipping the lower portion 114 of the shaper 106 of the hat insert 104 into the sweatband 103 of the hat 102 such that the upper portion 112 of the shaper 106 engages with the sidewall 123 of the hat 102. The method may further comprise securing the hat insert 104 in place by applying friction tabs 122 against interior surfaces of the hat 102. If the hat insert 104 is needed for use with a different hat (not shown), the hat insert 104 may be removed from the hat 102 by pulling the lower portion 114 of the shaper 106 out from the sweatband 103 of the hat 102 and disassociating friction tabs 122 from the interior of the hat 102, as needed. Once removed from the hat 102, the hat insert 104 may be cleaned or inserted into the different hat for further use.

Referring now to FIGS. 2, 3A, and 3B, there are depicted a side view of assembly of an exemplary shaper (FIG. 2), a top view of assembly of the exemplary hat insert by associating the exemplary shaper with an exemplary liner (FIG. 3A) and a top view of the exemplary hat insert after assembly (FIG. 3B). In implementations, the shaper 106 may be malleable to conform with and maintain a shape of the hat. The shaper 106 may include a malleable skeleton therein that comprises a primary member 110 with a plurality of secondary members 118 that extend therefrom. The primary member 110 may extend along a horizontal length of the shaper 106 and the secondary members 118 may extend vertically along lengths of the plurality of lower protrusions (i.e., arc-shaped portions of lower portion 114) and the plurality of upper protrusions 116 (i.e., plateau-shaped portions of upper portion 112) to provide additional support to the shaper 106. The malleable skeleton (FIG. 2 upper portion, malleable skeleton in solid lines) may include a flexible piece of plastic or a metallic wire and may be affixed to or inserted into the shaper 106 after constructing the shaper 106, or the shaper 106 may be formed around the malleable skeleton as part of construction of the shaper 106. After the malleable skeleton is within or otherwise attached to or associated with the shaper 106, the shaper 106 may be malleable as a result of this property of the malleable skeleton (FIG. 2 lower portion, malleable skeleton in broken lines). In this manner, any suitable degree of pliability (from the material of the shaper 106, e.g., a foam material) and malleability (from the material of the malleable skeleton, e.g., a metallic material) may be used for the shaper 106 to achieve a desired level of comfort and control as well as softness and firmness, according to need.

Accordingly, the disclosure also provides a method for producing the hat insert 104, the method comprising: constructing the shaper 106, constructing the liner 108, and associating the shaper 106 with the liner 108. The shaper 106 may be constructed by surrounding the malleable skeleton with a deformable material, such as the foam material, and the liner 108 may be constructed by cutting or sewing one, two, or more than two soft materials, such as silk, satin, nylon, and the like, configured to engage the wearer's hair or scalp and protect hair strands, hair follicles, and skin pores of the wearer from becoming damaged or soiled as a result of wearing an improved hat. The shaper 106 may be attached to the liner 108 by sewing, adhesive, and the like, whether in an inner space of the liner 108 or on an exterior surface of the liner 108. In implementations, the shaper 106 may be attached to the liner 108 such that some degree of overhang of the liner 108 covers the shaper 106 from being visible as part of the hat insert 104. The method may include attaching friction tabs (122 of FIGS. 1A and 1B) to the exterior of the liner 108 such that they are disposed at an interface between the hat insert 104 and the interior of the hat to prevent the hat insert 104 from moving or slipping relative to the hat during use.

In implementations, the hat may be a billed cap, such as a baseball hat (FIGS. 1A and 1B), which includes a hat aperture at a posterior portion thereof (not shown) which may comprise, for example, a snap of a Snapback-style baseball cap or a clasp for a hat fastener which allows the wearer to adjust the circumference of the hat. Accordingly, the liner 108 may include a liner aperture 128 (FIGS. 3A and 3B) positioned at a posterior portion of the liner 108 that is configured to align with the hat aperture of the hat. The liner aperture 128 may be defined by a liner fastener 126 (e.g., that is comprised of left liner fastener 126A and right liner fastener 126B which connect together) that is configured to secure the liner 108 at a diameter suitable for fitting the head of the wearer and to open or close a perimeter that defines the liner aperture 128. The liner fastener 126, including the left liner fastener 126A and the right liner fastener 126B, may comprise a snap, a hook and loop (Velcro®), or another suitable fastener according to need. Mating portions (126A, 126B) of the liner fastener 126 may be affixed to sections of the liner to allow these portions to be coupled together.

Accordingly, the disclosure provides improved hats, hat inserts, and related methods that may be used to produce a hat insert for protecting a hat and a wearer's hair and skin from becoming damaged or soiled during use. While the disclosure has been described in connection with what is presently considered to be the most practical and various embodiments, it is to be understood that the disclosure is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements comprised within the spirit and scope of the appended claims.

The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed, and modifications and variations are possible in view of the above teaching. The exemplary embodiment was chosen and described to best explain the principles of the present invention and its practical application, to thereby enable others skilled in the art to best utilize the present invention and its embodiments with modifications as suited to the use contemplated.

It is therefore submitted that the present invention has been shown and described in the most practical and exemplary embodiments. It should be recognized that departures may be made which fall within the scope of the invention. With respect to the description provided herein, it is submitted that the optimal features of the invention include variations in size, materials, shape, form, function and manner of operation, assembly, and use. All structures, functions, and relationships equivalent or essentially equivalent to those disclosed are intended to be encompassed by the present invention.

Claims

1. A hat insert comprising a shaper associated with a liner; wherein the shaper is configured to support a hat, and wherein the liner is configured to contact a head of a wearer when an improved hat that comprises the hat insert and the hat is worn by the wearer.

2. The hat insert of claim 1, wherein the shaper is attached to the liner.

3. The hat insert of claim 1, wherein the liner comprises a crown support that engages and supports a crown of the hat.

4. The hat insert of claim 1, wherein the liner comprises at least one friction tab that is configured to secure the hat insert to the interior of the hat and reduce movement of the hat insert relative to the hat.

5. The hat insert of claim 1, wherein the shaper comprises a material that deforms with application of a compressive force and reforms with removal of the compressive force.

6. The hat insert of claim 1, wherein at least a portion of the liner comprises a material that absorbs moisture.

7. The hat insert of claim 1, wherein the shaper comprises a lower portion that is removably insertable into a sweatband of the hat and an upper portion that is removably engageable with the interior of the hat, wherein the lower portion is delineated from the upper portion by a centerline of the shaper.

8. The hat insert of claim 7, wherein the lower portion comprises a plurality of lower protrusions separated by lower notches that prevent bulge and facilitate alignment of the shaper to the hat, and wherein the upper portion comprises a plurality of upper protrusions separated by upper notches that prevent bulge and support a sidewall of the hat.

9. The hat insert of claim 1, wherein the shaper is malleable to conform with and maintain a shape of the hat.

10. The hat insert of claim 9, wherein the shaper comprises a malleable skeleton therein, wherein the malleable skeleton comprises a primary member with a plurality of secondary members that extend therefrom.

11. The hat insert of claim 1, wherein the liner comprises a soft material that engages the wearer's hair or scalp and protects hair strands, hair follicles, and skin pores of the wearer from becoming damaged or soiled as a result of wearing the improved hat.

12. The hat insert of claim 11, wherein the soft material comprises silk, satin, nylon, or any combination thereof.

13. The hat insert of claim 1, wherein the hat is a billed cap with a hat aperture at a posterior portion thereof, and wherein the liner includes a liner aperture positioned at a posterior portion thereof that is configured to align with the hat aperture.

14. The hat insert of claim 13, wherein the liner aperture is defined by a liner fastener configured to secure the liner at a diameter suitable for fitting the head of the wearer.

15. An improved hat, comprising: a hat; anda hat insert removably attached to an interior of the hat, wherein the hat insert comprises a shaper associated with a liner;wherein the shaper is configured to support the hat, and wherein the liner is configured to contact a head of a wearer when the improved hat is worn by the wearer.

16. The improved hat of claim 15, wherein the shaper is attached to the liner, and wherein the liner comprises a crown support that engages and supports a crown of the hat and at least one friction tab that is configured to secure the hat insert to the interior of the hat and reduce movement of the hat insert relative to the hat, wherein at least a portion of the liner comprises a material that absorbs moisture;wherein the shaper comprises a material that deforms with application of a compressive force and reforms with removal of the compressive force.

17. The improved hat of claim 15, wherein the shaper comprises a lower portion removably inserted into a sweatband of the hat and an upper portion removably engaged with the interior of the hat, wherein the lower portion is delineated from the upper portion by a centerline of the shaper; wherein the lower portion comprises a plurality of lower protrusions separated by lower notches that prevent bulge and facilitate alignment of the shaper to the hat, and wherein the upper portion comprises a plurality of upper protrusions separated by upper notches that prevent bulge and support a sidewall of the hat.

18. The improved hat of claim 15, wherein the shaper is malleable to conform with and maintain a shape of the hat; wherein the shaper comprises a malleable skeleton therein, wherein the malleable skeleton comprises a primary member with a plurality of secondary members that extend therefrom.

19. The improved hat of claim 15, wherein the liner comprises a soft material that engages the wearer's hair or scalp and protects hair strands, hair follicles, and skin pores of the wearer from becoming damaged or soiled as a result of wearing the improved hat; wherein the soft material comprises silk, satin, nylon, or any combination thereof.

20. The improved hat of claim 15, wherein the hat is a billed cap with a hat aperture at a posterior portion thereof; wherein the liner includes a liner aperture positioned at a posterior portion thereof that is configured to align with the hat aperture, wherein the liner aperture is defined by a liner fastener configured to secure the liner at a diameter suitable for fitting the head of the wearer.