HEADWEAR INSERT, SYSTEM, AND METHODS TO DEFINE AND CONTROL THE SHAPE OF AN ARTICLE OF HEADWEAR

Abstract

A headwear insert, system, and methods to define and control the shape of an article of headwear are provided which may be used to change the shape of an already manufactured cap to the shape of the insert, completely changing the shape and style, and the headwear insert may include an elongated body having a first end, a second end, an elongated upper surface, an elongated lower surface, an elongated first side surface, an elongated second side surface, and a curved body section. The elongated upper surface, the elongated lower surface, the elongated first side surface, and the elongated second side surface may each extend between the first end and the second end, and the curved body section may be formed by a first portion of the elongated upper surface having a convex curve shape and by a first portion of the elongated lower surface having a concave curve shape.

Description

APPENDIX TO THE SPECIFICATION

The present application contains an appendix labeled as “Appendix-A”. The entire contents of which are hereby incorporated by reference.

FIELD OF THE INVENTION

This patent specification relates to the field of headwear. More specifically, this patent specification relates to devices, systems, and methods of defining and controlling the shape of headwear crowns and the like.

BACKGROUND

The shape of headwear is very important to the consumer. Headwear can lose its shape overtime through normal wear or damage. This problem is of particular concern for baseball style caps and other headwear having a crown, visor or brim. There are several different profiles and shapes to the crown (upper portion) of this type of headwear. Each consumer has their own likes and dislikes for the height and shape.

While some devices have been made to help with shaping of the crown of the headwear. These have mostly been bulky and do not help the headwear's shape enough and or is uncomfortable to wear. Other products are too soft and don't perform as they should. Other inserts have been made and are flat and don't resemble the shape of the headwear. While still others are made too thin to change or control the shape of headwear.

Therefore, a need exists for novel devices, systems, and methods of defining and controlling the shape of headwear crowns and the like. A further need exists for novel devices, systems, and methods which do not suffer from the above-mentioned drawbacks. There is also a need for novel devices, systems, and methods which are able to control the shape of headwear and also alter the shape of headwear.

BRIEF SUMMARY OF THE INVENTION

A headwear insert, system, and methods to define and control the shape of an article of headwear are provided.

According to one aspect consistent with the principles of the invention, a headwear insert is provided which may be used to define and control the shape of an article of headwear. In some embodiments, the headwear insert may include an elongated body having a first end, a second end, an elongated upper surface, an elongated lower surface, an elongated first side surface, an elongated second side surface, and a curved body section. The elongated upper surface, the elongated lower surface, the elongated first side surface, and the elongated second side surface may each extend between the first end and the second end, and the curved body section may be formed by a first portion of the elongated upper surface having a convex curve shape and by a first portion of the elongated lower surface having a concave curve shape. The headwear insert may have a length dimension that describes a length of the elongated upper surface between the first end and the second end, and the curved body section may be at least fifty percent of the length dimension.

According to another embodiment consistent with the present invention, a headwear insert system is provided. In some embodiments, a headwear insert system may include an article of headwear and one or more headwear inserts that may be coupled to the article of headwear. Each headwear insert headwear insert may be coupled to the crown of the article of headwear between two adjacent crown segments so that the headwear insert is positioned between a crown seam and seam tape covering the crown seam and so that the elongated body of the headwear insert is substantially parallel to the crown seam.

According to another embodiment consistent with the principles of the invention, a method of manufacturing an article of headwear is provided. The method may be used to define and to control the shape of the crown of an article of headwear during and after manufacturing, such as structured and unstructured baseball caps. In some embodiments, the method may include the steps of: assembling a crown by coupling the crown segments together in side-by-side relationship with side edges of the crown segments extending upwardly from the crown bottom perimeter to the crown top and each crown segment being coupled to its adjacent crown segment along a crown seam adjacent to the side edges; coupling a headwear insert to a crown seam between two adjacent crown segments so that the headwear insert is positioned between a crown seam and seam tape covering the crown seam of two adjacent crown segments; and coupling the visor to the crown.

According to another embodiment consistent with the principles of the invention, a method of changing the shape of an article of headwear using a headwear insert according to various embodiments described herein is provided. The method may be used to define and to control the shape of the crown of an existing article of headwear, such as structured and unstructured baseball caps, after it has been manufactured. In some embodiments, the method may include the steps of: inserting the headwear insert between a desired seam tape and the crown seam of an article of headwear; and positioning the elongated body of headwear insert between the seam tape and the crown seam and between the crown bottom perimeter and the crown top so that the elongated body of the headwear insert is substantially parallel (plus or minus 5 degrees) to the crown seam.

Numerous objects, features and advantages of the present invention will be readily apparent to those of ordinary skill in the art. Some example objects of the present invention are listed below.

One object of the present invention is to provide a headwear insert and methods that may be used to define and to control the shape of an article of headwear during and after manufacturing without requiring the changing of the shape of crown segments, as existing methods of manufacturing an article of headwear must utilize different shaped crown segments to produce articles of headwear having different shaped crowns.

Another object is to provide a headwear insert and methods that may be used to define and to control the shape of an article of headwear during and after manufacturing without requiring the steps of blocking, steaming, and pressure shaping, all of which are required in existing methods of manufacturing an article of headwear.

Another object is to provide a headwear insert and methods that is able to change the shape of an already manufactured article of headwear, such that a headwear insert and methods using the same are able to change the shape of a crown's profile of an already manufactured cap or other article of headwear to the shape of the headwear insert, completely changing the shape and style of the article of headwear.

BRIEF DESCRIPTION OF THE DRAWINGS

Some embodiments of the present invention are illustrated as an example and are not limited by the figures of the accompanying drawings, in which like references may indicate similar elements and in which:

FIG. 1—FIG. 1 depicts a side elevation view of an example of a headwear insert according to various embodiments described herein.

FIG. 2—FIG. 2 illustrates a side perspective view of an example of a headwear insert according to various embodiments described herein.

FIG. 3—FIG. 3 shows another side elevation view of an example of a headwear insert according to various embodiments described herein.

FIG. 4—FIG. 4 depicts a side elevation view of another example of a headwear insert according to various embodiments described herein.

FIG. 5—FIG. 5 illustrates a side perspective view of another example of a headwear insert according to various embodiments described herein.

FIG. 6—FIG. 6 shows another side elevation view of another example of a headwear insert according to various embodiments described herein.

FIG. 7—FIG. 7 depicts a front elevation view of a headwear insert system having an article of headwear according to various embodiments described herein.

FIG. 8—FIG. 8 illustrates a rear elevation view of a headwear insert system having an article of headwear according to various embodiments described herein.

FIG. 9—FIG. 9 shows a first side elevation view of a headwear insert system having an article of headwear according to various embodiments described herein.

FIG. 10—FIG. 10 depicts a second side elevation view of a headwear insert system having an article of headwear according to various embodiments described herein.

FIG. 11—FIG. 11 illustrates a sectional, through line 11-11 shown in FIG. 7, elevation view of an example of a headwear insert system having an article of headwear according to various embodiments described herein.

FIG. 12—FIG. 12 shows a block diagram of an example of a method of manufacturing an article of headwear using a headwear insert according to various embodiments described herein.

FIG. 13—FIG. 13 illustrates the positioning of a headwear insert during the method of manufacturing an article of headwear using a headwear insert of FIG. 12 according to various embodiments described herein.

FIG. 14—FIG. 14 depicts a block diagram of an example of a method of changing the shape of an article of headwear using a headwear insert according to various embodiments described herein.

FIG. 15—FIG. 15 shows the positioning of a headwear insert during the method of changing the shape of an article of headwear using a headwear insert of FIG. 14 according to various embodiments described herein.

DETAILED DESCRIPTION OF THE INVENTION

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well as the singular forms, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one having ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

In describing the invention, it will be understood that a number of techniques and steps are disclosed. Each of these has individual benefit and each can also be used in conjunction with one or more, or in some cases all, of the other disclosed techniques. Accordingly, for the sake of clarity, this description will refrain from repeating every possible combination of the individual steps in an unnecessary fashion. Nevertheless, the specification and claims should be read with the understanding that such combinations are entirely within the scope of the invention and the claims.

For purposes of description herein, the terms “upper,” “lower,” “left,” “right,” “rear,” “front,” “side,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in FIG. 1. However, one will understand that the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary. Therefore, the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

Although the terms “first,” “second,” etc. are used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another element. For example, the first element may be designated as the second element, and the second element may be likewise designated as the first element without departing from the scope of the invention.

As used in this application, the term “about” or “approximately” refers to a range of values within plus or minus 15% of the specified number. Additionally, as used in this application, the term “substantially” means that the actual value is within about 10% of the actual desired value, more preferably within about 5% of the actual desired value and even more preferably within about 1% of the actual desired value of any variable, element or limit set forth herein.

A new headwear insert, system, and methods to define and control the shape of an article of headwear are discussed herein. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be evident, however, to one skilled in the art that the present invention may be practiced without these specific details.

The present disclosure is to be considered as an exemplification of the invention and is not intended to limit the invention to the specific embodiments illustrated by the figures or description below.

The present invention will now be described by example and through referencing the appended figures representing preferred and alternative embodiments. FIGS. 1-6 illustrate examples of a headwear insert 100A, 100B, according to various embodiments, which may be used to define and control the shape of an article of headwear 150. In some embodiments, the headwear insert 100A, 100B, may comprise an elongated body 11 having a first end 12, a second end 13, an elongated upper surface 14, an elongated lower surface 15, an elongated first side surface 16, an elongated second side surface 17, and a curved body section 21. The elongated upper surface 14, the elongated lower surface 15, the elongated first side surface 16, and the elongated second side surface 17 may each extend between the first end 12 and the second end 13, and the curved body section 21 may be formed by a first portion 14A of the elongated upper surface 14 having a convex curve shape and by a first portion 15A of the elongated lower surface 15 having a concave curve shape.

The headwear insert 100A, 100B, may comprise an elongated body 11 that may be pre-formed with a desired shape, such as by having at least one curved body section 21, and that may be made from or may comprise a resilient material may be flexible to allow slight deformation and resilient so as to return to its original shape after deformation. Resilient materials may include flexible plastics, such as high-density polyethylene (HDPE), polyvinyl chloride (PVC), polypropylene (PP), Polystyrene (PS), Polycarbonate (PC), low density polyethylene (LDPE), or any other flexible material including combinations of materials. In some embodiments, the headwear insert 100A, 100B, may comprise a plastic material that may be formed using injection molding, thermoforming, or other suitable forming method.

The elongated body 11 may be configured in any size and shape. In preferred embodiments, the elongated body 11 may be elongated having a length dimension L1 that may describe a length of the elongated upper surface 14 between the first end 12 and the second end 13, and the length dimension L1 may be much larger, such as by being greater that 500 percent larger, than the width W of the elongated body 11 (distance between the elongated first side surface 16 and elongated second side surface 17). The length dimension L1 may also be much larger, such as by being greater than 800 percent larger, than the thickness T of the elongated body 11 (distance between the elongated upper surface 14 and elongated lower surface 15).

In some embodiments, the width W of the elongated body 11 described by the distance between the elongated first side surface 16 and elongated second side surface 17, may be approximately uniform along the length dimension L1. In preferred embodiments, the elongated body 11 may comprise a width W of between 0.35 and 0.10 inches, and more preferably a width W of between 0.3 and 0.15 inches. Generally, the larger the width, the more resistant the elongated body 11 may be to deformation. In preferred embodiments, the elongated first side surface 16 and the elongated second side surface 17 may be substantially parallel to each other along the length dimension L1, such as plus or minus five degrees.

In some embodiments, the thickness T of the elongated body 11 described by the distance between the elongated upper surface 14 and the elongated lower surface 15, may be substantially uniform along the length dimension L1. In preferred embodiments, the elongated body 11 may comprise a thickness T of between 0.8 and 0.4 inches, and more preferably a thickness T of between 0.65 and 0.55 inches. In further embodiments, the elongated body 11 may comprise a thickness T of between 0.1 and 0.4 inches, and more preferably a thickness T of between 0.15 and 0.25 inches. Generally, the larger the thickness T, the more resistant the elongated body 11 may be to deformation.

The elongated body 11 may comprise a curved body section 21. In preferred embodiments, the elongated body 11 may comprise a curved body section 21 that may be formed by a first portion 14A of the elongated upper surface 14 having a convex curve shape and by a first portion 15A of the elongated lower surface 15 having a concave curve shape.

In some embodiments, and as shown in FIGS. 1-3, the first portion 15A of the elongated lower surface may have a concave curve shape, in which at least a portion of the concave curve shape has an arc length A1 of between 24 and 34 degrees and a radius R1 of between 2.0 and 3.0 inches. In preferred embodiments, the first portion 15A of the elongated lower surface may have a concave curve shape, in which at least a portion of the concave curve shape has an arc length A1 of between 27 and 31 degrees, and more preferably substantially 29 degrees and a radius R1 of between 2.3 and 2.7 inches, and more preferably substantially 2.5 inches.

In some embodiments, and as perhaps best shown in FIG. 4-6, the first portion 14A of the elongated upper surface 14 may have a substantially uniform convex curve shape and the first portion 15A of the elongated lower surface 15 may have a substantially uniform concave curve shape. In further embodiments, and as perhaps best shown in FIG. 305, the first portion 14A of the elongated upper surface 14 may have a complex convex curve shape, having two or more arc lengths and radii, and the first portion 15A of the elongated lower surface 15 may have a complex convex curve shape, having two or more arc lengths and radii.

In some embodiments, and as shown in FIGS. 4-6, the first portion 15A of the elongated lower surface may have a concave curve shape having a concave curve shape defined by an arc length A2 of between 60 and 80 degrees and a radius R2 of between 3.0 and 4.2 inches. In preferred embodiments, the first portion 15A of the elongated lower surface may have a concave curve shape has the concave curve shape defined by an arc length A2 of between 65 and 75 degrees, and more preferably substantially 70 degrees and a radius R2 of between 3.4 and 4.5 inches, and more preferably substantially 3.6 inches.

In some embodiments, the headwear insert 100A, 100B, may comprise a linear body section 31, and the linear body section 31 may be formed by a second portion 14B of the elongated upper surface 14 having a planar shape and by a second portion 15B of the elongated lower surface 15 having a planar shape. In preferred embodiments, the second portion 14B of the elongated upper surface 14 and the second portion 15B of the elongated lower surface 15 may be substantially parallel to each other, such as plus or minus five degrees.

In preferred embodiments, the elongated body 11 may comprise a length dimension L1 that may be between 5.5 inches and 6.5 inches, and more preferably between 5.65 inches and 6.1 inches. In further preferred embodiments, the headwear insert 100A, 100B, may comprise a curved body section 21 that may comprise at least fifty percent of the length dimension L1, and the headwear insert 100A, 100B, may comprise a linear body section 31 that may comprise less than fifty percent of the length dimension L1. Optionally, the headwear insert 100A, 100B, may comprise a curved body section 21 and a linear body section 31 that together may comprise 100 percent of the length dimension L1.

In some embodiments, and as shown in FIGS. 4-6, the headwear insert 100A, 100B, may comprise a curved body section 21 that may comprise approximately 70 to 85 percent of the length dimension L1, and the headwear insert 100A, 100B, may comprise a linear body section 31 that may comprise approximately 15 to 30 percent of the length dimension L1. For example, the length dimension L1 may be approximately 5.75 inches, the curved body section 21 may have a length dimension (LC) that may be approximately 3.95 to 4.85 inches, and the linear body section 31 may have a length dimension (LL) that may be approximately 0.9 to 1.8 inches length dimension (LL).

In some embodiments, and as shown in FIGS. 1-3, the headwear insert 100A, 100B, may comprise a curved body section 21 that may comprise approximately 50 to 70 percent of the length dimension L1, and the headwear insert 100A, 100B, may comprise a linear body section 31 that may comprise approximately 30 to 50 percent of the length dimension L1. For example, the length dimension L1 may be approximately 6.0 inches, the curved body section 21 may have a length dimension (LC) that may be approximately 3.0 to 4.2 inches, and the linear body section 31 may have a length dimension (LL) that may be approximately 1.8 to 3.0 inches.

According to another embodiment consistent with the present invention, a headwear insert system 125 (FIGS. 7-11, 13, and 15) is provided. In some embodiments, a headwear insert system 125 may comprise an article of headwear 150 and one or more headwear inserts 100A, 100B, that may be coupled to the article of headwear 150. Each headwear insert headwear insert 100A, 100B, may be coupled to the crown 151 of the article of headwear 150 between two adjacent crown segments 155 so that the headwear insert 100A, 100B, is positioned between a crown seam 157 and seam tape 158 covering the crown seam 157 and so that the headwear insert 100A, 100B, is substantially parallel to the crown seam 157.

Referring to FIG. 12, a method of manufacturing an article of headwear 150 using one or more headwear inserts 100A, 100B, (“the method”) 200 according to various embodiments described herein is provided. The method 200 may be used to define and to control the shape of an article of headwear 150 during and after manufacturing, such as structured and unstructured baseball caps. It is important to point out that method 300 may be used to define and to control the shape of an article of headwear 150 during and after manufacturing without requiring the changing of the shape of crown segments 155, as existing methods of manufacturing an article of headwear must utilize different shaped crown segments 155 to produce articles of headwear 150 having different shaped crowns 151. It is important to point out that method 300 may be used to define and to control the shape of an article of headwear 150 during and after manufacturing without requiring the steps of blocking, streaming, and pressure shaping, all of which are required in existing methods of manufacturing an article of headwear.

In preferred embodiments, the method 200 may be used to manufacture an article of headwear 150 having a crown 151, a crown bottom perimeter 152, a crown top 153, and a visor 154, using one or more headwear inserts 100A, 100B. Each headwear insert 100A, 100B, may be coupled to the crown 151 of the article of headwear 150 between two adjacent crown segments 155 so that the headwear insert 100A, 100B, is positioned between a crown seam 157 and seam tape 158 covering the crown seam 157 and so that the headwear insert 100A, 100B, is substantially parallel to the crown seam 157, such as shown in the example of FIG. 13.

In some embodiments, the method 200 may start 201, and the crown 151 may be assembled by coupling a plurality of crown segments 155 together in side-by-side relationship with side edges 156 of the crown segments 155 extending upwardly from the crown bottom perimeter 152 (typically formed by the bottom of the sweat band 159 (FIG. 11) to the crown top 153 and each crown segment 155 being coupled to its adjacent crown segment 155 along a crown seam 157 adjacent to the side edges 156 in step 202.

In step 203, a headwear insert headwear insert 100A, 100B, may be coupled to the crown 151 proximate to a first crown seam 157 of two adjacent crown segments 155 so that the headwear insert 100A, 100B, is positioned between the first crown seam 157 and seam tape 158 covering the first crown seam 157. In preferred embodiments and as shown in FIGS. 1-6, the headwear insert headwear insert 100A, 100B, may have an elongated body 11 having a length dimension L1, a first end 12, a second end 13, an elongated upper surface 14, an elongated lower surface 15, an elongated first side surface 16, an elongated second side surface 17, and a curved body section 21. The elongated upper surface 14, the elongated lower surface 15, the elongated first side surface 16, and the elongated second side surface 17 may each extend between the first end 12 and the second end 13, and the length dimension L1 may describe a length of the elongated upper surface 14 between the first end 12 and the second end 13. The curved body section 21 may comprise at least fifty percent of the length dimension L1, and the curved body section 21 may be formed by a first portion 14A of the elongated upper surface 14 having a convex curve shape and by a first portion 15A of the elongated lower surface 15 having a concave curve shape. In further preferred embodiments, step 202 may be repeated to couple a desired number of headwear inserts 100A, 100B, to the crown 151, with each headwear inserts 100A, 100B, coupled between two adjacent crown segments 155 so that each headwear insert 100A, 100B, is positioned between a crown seam 157 and seam tape 158 covering the crown seam 157. For example, a headwear insert 100A, 100B, may be coupled between each crown seam 157 and seam tape 158 that are proximate to the visor 154.

In preferred embodiments of step 203 the headwear insert 100A, 100B, may extend between 65 and 100 percent, and more preferably between 80 and 100 percent, of a distance (HD) between the crown bottom perimeter 152 and the crown top 153 as shown in FIG. 11. For example, if distance (HD) between the crown bottom perimeter 152 and the crown top 153 is 6.0 inches, length dimension L1 of the elongated body 11 may be between 4.8 and 6.0 inches.

In step 204, the visor 154 may be coupled to the crown 151, such as with stitching, heat bonding, or any other suitable coupling device or method.

After step 204, the method 200 may finish 205.

Referring to FIG. 14, a method of changing the shape of an article of headwear 150 using a headwear insert 100A, 100B, (“the method”) 300 according to various embodiments described herein is provided. The method 300 may be used to define and to control the shape of an existing article of headwear 150, such as structured and unstructured baseball caps, after it has been manufactured.

In preferred embodiments, the method 300 may be used with an article of headwear 150 having a crown 151 comprising a crown bottom perimeter 152 and a crown top 153, the crown 151 including a first crown segment 155 and a second crown segment 155 located in side-by-side relationship, with side edges 156 of the first crown segment 155 and the second crown segment 155 extending upwardly from the crown bottom perimeter 152 to the crown top 153 and the first crown 155 segment being fastened to the second crown segment 155 along a crown seam 157 with a seam tape 158 coupled over the crown seam 157 to the first crown segment 155 and the second crown segment 155.

In some embodiments, the method 300 may start 301, and a headwear insert 100A, 100B, may be inserted between a desired seam tape 158 and crown seam 157 in step 302, such as shown in the example of FIG. 15. In preferred embodiments, the seam tape 158 may be cut or slit to make an opening that a headwear insert 100A, 100B, may be inserted through so that the first end 12 or second end 13 of the headwear insert 100A, 100B, may be positioned between the desired seam tape 158 and crown seam 157. Preferably, a seam tape 158 may be cut or slit proximate to the crown bottom perimeter 152 or proximate to the crown top 153 to make an opening that a headwear insert 100A, 100B, may be inserted through.

In some embodiments, the method 300 may be used with an article of headwear 150 that has already been manufactured and which includes seam tape 158 that has been made to resemble a pocket during production. For example, the seam tape 158 may not come all the way down to the crown bottom perimeter 152 or bottom of the crown 151. The purpose of this is so that the headwear insert 100A, 100B, can be changed easily and any pre-shaped headwear insert 100A, 100B, can be used to change the shape of the crown 151 to the desired shape.

In preferred embodiments and as shown in FIGS. 1-6, the headwear insert 100A, 100B, may have an elongated body 11 having a length dimension L1, a first end 12, a second end 13, an elongated upper surface 14, an elongated lower surface 15, an elongated first side surface 16, an elongated second side surface 17, and a curved body section 21. The elongated upper surface 14, the elongated lower surface 15, the elongated first side surface 16, and the elongated second side surface 17 may each extend between the first end 12 and the second end 13, and the length dimension L1 may describe a length of the elongated upper surface 14 between the first end 12 and the second end 13. The curved body section 21 may comprise at least fifty percent of the length dimension L1, and the curved body section 21 may be formed by a first portion 14A of the elongated upper surface 14 having a convex curve shape and by a first portion 15A of the elongated lower surface 15 having a concave curve shape. In further preferred embodiments, step 302 may be repeated to couple a desired number of headwear inserts 100A, 100B, to the crown 151, with each headwear inserts 100A, 100B, coupled between two adjacent crown segments 155 so that each headwear insert 100A, 100B, is positioned between a crown seam 157 and seam tape 158 covering the crown seam 157. For example, a headwear insert 100A, 100B, may be coupled between each crown seam 157 and seam tape 158 that are proximate to the visor 154.

In step 303, the elongated body 11 of the headwear insert 100A, 100B, may be positioned between the seam tape 158 and the crown seam 157 and between the crown bottom perimeter 152 and the crown top 153. In preferred embodiments, the entire elongated body 11 of the headwear insert 100A, 100B, may be positioned between the seam tape 158 and the crown seam 157 and between the crown bottom perimeter 152 and the crown top 153 so that the elongated body is substantially parallel (plus or minus 5 degrees) to the crown seam 157. In preferred embodiments of step 303 the headwear insert may extend between 80 and 100 percent, and more preferably between 80 and 100 percent, of a distance (HD) between the crown bottom perimeter 152 and the crown top 153 as shown in FIG. 11. For example, if distance (HD) between the crown bottom perimeter 152 and the crown top 153 is 6.0 inches, length dimension L1 of the elongated body 11 may be between 4.8 and 6.0 inches.

After step 303, the method 300 may finish 304.

While some exemplary shapes and sizes have been provided for elements of the headwear insert 100A, 100B, it should be understood to one of ordinary skill in the art that the elongated body 11 and any other element described herein may be configured in a plurality of sizes and shapes including “T” shaped, “X” shaped, square shaped, rectangular shaped, cylinder shaped, cuboid shaped, hexagonal prism shaped, triangular prism shaped, or any other geometric or non-geometric shape, including combinations of shapes. It is not intended herein to mention all the possible alternatives, equivalent forms or ramifications of the invention. It is understood that the terms and proposed shapes used herein are merely descriptive, rather than limiting, and that various changes, such as to size and shape, may be made without departing from the spirit or scope of the invention.

In some embodiments, one or more of the elements that comprise the headwear insert 100A, 100B, may be coupled or connected together with heat bonding, chemical bonding, by being integrally formed or molded together, or any other suitable joining method.

Although the present invention has been illustrated and described herein with reference to preferred embodiments and specific examples thereof, it will be readily apparent to those of ordinary skill in the art that other embodiments and examples may perform similar functions and/or achieve like results. All such equivalent embodiments and examples are within the spirit and scope of the present invention, are contemplated thereby, and are intended to be covered by the following claims.

Claims

1. A headwear insert, the headwear insert comprising: an elongated body having a length dimension, a first end, a second end, an elongated upper surface, an elongated lower surface, an elongated first side surface, an elongated second side surface, and a curved body section, wherein the elongated upper surface, the elongated lower surface, the elongated first side surface, and the elongated second side surface each extend between the first end and the second end, wherein the length dimension describes a length of the elongated upper surface between the first end and the second end, wherein the curved body section comprises at least fifty percent of the length dimension, and wherein the curved body section is formed by a first portion of the elongated upper surface having a convex curve shape and by a first portion of the elongated lower surface having a concave curve shape.

2. The headwear insert of claim 1, wherein the elongated first side surface and the elongated second side surface are substantially parallel to each other.

3. The headwear insert of claim 1, further comprising a linear body section, wherein the linear body section is formed by a second portion of the elongated upper surface having a planar shape and by a second portion of the elongated lower surface having a planar shape.

4. The headwear insert of claim 3, wherein the second portion of the elongated upper surface and the second portion of the elongated lower surface are substantially parallel to each other.

5. The headwear insert of claim 1, wherein the first portion of the elongated lower surface having a concave curve shape has the concave curve shape defined by an arc length of between 60 and 80 degrees and a radius of between 3.0 and 4.2 inches.

6. The headwear insert of claim 1, wherein the first portion of the elongated lower surface having a concave curve shape has the concave curve shape defined by an arc length of between 34 and 24 degrees and a radius of between 2.0 and 3.0 inches.

7. A method of manufacturing an article of headwear, having a crown, a crown bottom perimeter, a crown top, and a visor, using a headwear insert, the method comprising: assembling the crown by coupling a plurality of crown segments together in side-by-side relationship with side edges of the crown segments extending upwardly from the crown bottom perimeter to the crown top and each crown segment being coupled to its adjacent crown segment along a crown seam adjacent to the side edges;coupling the headwear insert to the crown proximate to a first crown seam of two adjacent crown segments so that the headwear insert is positioned between the first crown seam and seam tape covering the first crown seam, the headwear insert having an elongated body having a length dimension, a first end, a second end, an elongated upper surface, an elongated lower surface, an elongated first side surface, an elongated second side surface, and a curved body section, wherein the elongated upper surface, the elongated lower surface, the elongated first side surface, and the elongated second side surface each extend between the first end and the second end, wherein the length dimension describes a length of the elongated upper surface between the first end and the second end, wherein the curved body section comprises at least fifty percent of the length dimension, and wherein the curved body section is formed by a first portion of the elongated upper surface having a convex curve shape and by a first portion of the elongated lower surface having a concave curve shape; andcoupling the visor to the crown.

8. The method of claim 7, wherein the headwear insert extends between 80 and 100 percent of a distance between the crown bottom perimeter and the crown top.

9. The method of claim 7, wherein the elongated first side surface and the elongated second side surface are substantially parallel to each other.

10. The method of claim 7, further comprising a linear body section, wherein the linear body section is formed by a second portion of the elongated upper surface having a planar shape and by a second portion of the elongated lower surface having a planar shape.

11. The method of claim 10, wherein the second portion of the elongated upper surface and the second portion of the elongated lower surface are substantially parallel to each other.

12. The method of claim 7, wherein the first portion of the elongated lower surface having a concave curve shape has the concave curve shape defined by an arc length of between 60 and 80 degrees and a radius of between 3.0 and 4.2 inches.

13. The method of claim 7, wherein the first portion of the elongated lower surface having a concave curve shape has the concave curve shape defined by an arc length of between 34 and 24 degrees and a radius of between 2.0 and 3.0 inches.

14. A method of changing the shape of an article of headwear using a headwear insert, the article of headwear comprising a crown having a crown bottom perimeter and a crown top, the crown including a first crown segment and a second crown segment located in side-by-side relationship, with side edges of the first crown segment and the second crown segment extending upwardly from the crown bottom perimeter to the crown top and the first crown segment being fastened to the second crown segment along a crown seam with a seam tape coupled over the crown seam to the first crown segment and the second crown segment, the method comprising: inserting the headwear insert between the seam tape and the crown seam, the headwear insert having an elongated body having a length dimension, a first end, a second end, an elongated upper surface, an elongated lower surface, an elongated first side surface, an elongated second side surface, and a curved body section, wherein the elongated upper surface, the elongated lower surface, the elongated first side surface, and the elongated second side surface each extend between the first end and the second end, wherein the length dimension describes a length of the elongated upper surface between the first end and the second end, wherein the curved body section comprises at least fifty percent of the length dimension, and wherein the curved body section is formed by a first portion of the elongated upper surface having a convex curve shape and by a first portion of the elongated lower surface having a concave curve shape; andpositioning the elongated body of the headwear insert between the seam tape and the crown seam and between the crown bottom perimeter and the crown top.

15. The method of claim 14, wherein the headwear insert extends between 80 and 100 percent of a distance between the crown bottom perimeter and the crown top.

16. The method of claim 14, wherein the elongated first side surface and the elongated second side surface are substantially parallel to each other.

17. The method of claim 14, further comprising a linear body section, wherein the linear body section is formed by a second portion of the elongated upper surface having a planar shape and by a second portion of the elongated lower surface having a planar shape.

18. The method of claim 17, wherein the second portion of the elongated upper surface and the second portion of the elongated lower surface are substantially parallel to each other.

19. The method of claim 14, wherein the first portion of the elongated lower surface having a concave curve shape has the concave curve shape defined by an arc length of between 60 and 80 degrees and a radius of between 3.0 and 4.2 inches.

20. The method of claim 14, wherein the first portion of the elongated lower surface having a concave curve shape has the concave curve shape defined by an arc length of between 34 and 24 degrees and a radius of between 2.0 and 3.0 inches.