BACKGROUND OF THE INVENTION

TECHNICAL FIELD

This invention is directed to hats. More specifically, this direction is directed to hats or caps. Most particularly, this direction is directed to a cap which includes a protective insert. Specifically, the cap has the appearance of a traditional ball cap and the insert includes a rigid shell and an impact absorbent liner, where each of the shell and liner include projects which extend below the bottom edge of the cap to at least partially cover the user's temples.

BACKGROUND INFORMATION

One of the issues that tee-ball, baseball and Softball users may experience is that a struck ball, such as one hit in a line drive, or a bat that is accidentally released may strike a user in the head, causing an impact injury such as a concussion, a fracture or catastrophic impacts that may cause intracranial bleeding leading to death. This is particularly problematic when it comes to ball games played by younger, less experienced and less skilled users who may not be able to direct a struck ball in a particular direction with any certainty. This type of injury may also occur if a ball or bat strikes a spectator by accident.

While many users, such as batters wear protective helmets, a large percentage of users do not or will not wear such protective gear. Additionally, it is highly unlikely that any spectator will be wearing some type of protective helmet when they show up to watch a game. Traditionally both users and spectators prefer to wear a traditional baseball cap.

There have been a number of attempts made in the past to provide protection on the outside of a ball cap, but the fact is if the protective components cover the "team" logo or if the hat looks bulky and somehow not traditional, children, in particular, will not wear such a cap.

There have also been numerous attempts at providing protective components in interiors of hats but many of the resultant products have been bulky and unsightly and therefore less desirable for people to wear.

Examples of previously known devices include that disclosed in US Patent No. 3,268,911 (Cox). Cox discloses a conventional hat having a dome-shaped protective i shell made of hard plastic received therein. The shell is configured complementary to the inner surface of the hat and fits snugly within the space defined by the hat's inner surface. A generally X-shaped harness assembly made of a flexible plastic is disposed within a space defined by the shell. The harness is secured to a bottom region of the shell by cooperating buttons and holes disposed on the shell and harness. When the harness is engaged in the shell, a crown-region of the harness rests on the top of the user's head and the crown-region is disposed a distance downwardly away from the protective shell. An annular sweatband is secured to the ends of the harness and is disposed aligned with an annular bottom region of the shell and inside the bottom edge of the hat. Resilient pads are glued at intervals to the inner surface of the shell. In particular, the pads are provided at the crown region of the shell and at spaced temple positions around the circumference of the shell. The spacing between the pads allows for ventilation of the hat. The harness engages the user's head and the protective pads and the shell are thereby disposed a short distance from the user's head. The user's head is not in contact with the pads.

Graham (US 4,982,451 ) discloses a resilient adjustable liner for a hat, particularly a soft, yarn hat. The liner is fabricated from a resilient and flexible plastic that is U- shaped when viewed from the top. The liner includes a central region that is configured to be disposed adjacent the back of a user's head and two side regions that are configured to extend downwardly over the user's cheeks. A slot in the band is positionable over the user's forehead. The liner is of uniform thickness along its entire length. Plastic fasteners engage the liner to the hat. Apertures are provided in the liner in a location which will fall adjacent the user's ears. The hat is pulled over the liner and covers the entire liner.

Benston et al (US 5,025,504) discloses a disposable liner for a hat or cap which is an elongate, trapezoidally-shaped member that is adhered to a portion of the inner surface of the hat or cap. The liner includes a central region for positioning adjacent the user's forehead and two tapering side regions extending outwardly from the central region. The side regions are configured so as to extend across the region of the user's head across the upper regions of their temples. The liner is designed as a sweatband and includes a liquid absorbing material disposed between an interior and exterior wall. The liquid absorbing material is disposed in discrete pockets which are separated from each other by regions which are free of liquid absorbing material. Leach (US 5,226,180) discloses a golfing helmet that includes an outer hat or cap that is conventional. An impact absorbing Styrofoam liner is placed in the interior of the cap. The hemispherical liner includes elongate openings for ventilation. The liner is glued into the cap. Similarly, Anderson (US 5,289,591 ) discloses a plastic insert for a golf cap. The insert is generally hemispherical except for a semi-circular cut-out in the back of the insert which allows for adjustment of the cap. The insert is provided with apertures for ventilation.

U.S. Patent No. 5,437,064 (Hamaguchi) discloses a protective cap that includes a first padding assembly comprising a circular band that is configured to encircle a user's head and be seated inside the bottom edge of a hat. The first padding assembly also includes two semi-circular bands which are connected to the circular band and are configured to pass from front-to-back and from side-to-side across the crown of the user's head. The first padding assembly is detachably secured to the inside of the hat by way of hook and loop fasteners. The protective cap further includes a second padding assembly which is received within a space defined by the first padding assembly. The second padding assembly includes an outer fabric layer and an inner resilient foam layer. The second padding assembly is configured to contact the user's head.

Moore, III et al (U.S. 6,154,889) discloses a protective helmet made from a resilient shell that has a plurality of radial slits therein which enable the shell's width to be adjusted. The shell is fabricated from a hard material and a liner fabricated from an energy absorbing material is disposed inside the shell. The shell is a hemispherical dome and includes regions which extend downwardly to cover a user's temples.

Blair (US 7,096,512) discloses a protective sports hat insert which includes a solid outer shell, an inner high-density foam liner, and may include a washable cloth layer. The outer shell is domed and hemispherical in shape and the inner liner is complementary in shape to the outer shell. The inner liner may be fabricated in a variety of configurations that may be "folded into" the space defined by the outer shell. Preferably, inner liner is spaced from outer shell to provide some additional shock absorption when the hat receives an impact blow. The inner liner tapers at its bottom edge.

Motroni (US 2012/0131731 ) discloses an insert for a ball cap. The insert is configured to extend along the front wall of the cap and thereby protect the forehead of the user. The insert is made from plastic and may be placed adjacent the front wall or be glued or otherwise secured in place.

While all of the above protective devices work adequately for the purposes for which they were intended, there remains a need in the art for an improved protective cap which has the outward appearance of a traditional cap but which aids in protecting the most vulnerable areas of the user's head.

SUMMARY

A protective insert for a ball cap and a cap incorporating the same are disclosed. The insert includes a rigid, U-shaped outer shell and a complementary impact absorbent liner. The insert covers and protects only the forehead, temples and portions of the sides of the user's head. The shell and liner have bottom edges disposed inwardly relative to a bottom edge of the cap. Projections provided on the shell and liner extend downwardly beyond the cap's bottom edge and cover the user's temples. Adjustable bands and straps secured to the shell retain the insert on the user's head. One or more engagement members secure the insert to the cap. The material of the liner is thicker in a front central region and thinner toward the side regions of the insert. The liner material extends beyond the peripheral edges of the shell so that the shell does not directly contact the user's head.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

A sample embodiment of the invention, illustrative of the best mode in which Applicant contemplates applying the principles, is set forth in the following description, is shown in the drawings and is particularly and distinctly pointed out and set forth in the appended claims.

Fig. 1 shows a perspective view of a ball cap in accordance with an aspect of the present invention with the cap being shown worn on a user's head;

Fig. 2 is a perspective view of the insert for the ball cap shown worn on the user's head;

Fig. 3 is a perspective view of the insert removed from the user's head;

Fig. 4 is an exploded perspective view of the insert of Fig. 3;

Fig. 5 is a top view of the insert;

Fig. 6 is a left side view of the insert;

Fig. 7 is a front plan view of the insert; Fig. 8 is a bottom perspective view of the insert;

Fig. 9 is an enlarged perspective view of the highlighted region of Fig.3;

Fig. 10 is a cross-sectional side view of the ball cap with insert engaged therewith shown worn on a user's head; and

Fig. 11 is a cross-sectional front view of the ball cap and insert worn on a user's head with the cross-section being taken along line 11 -11 of Fig. 6.

Similar numbers refer to similar parts throughout the drawings.

DETAILED DESCRIPTION

Referring to Figs. 1-11 , there is shown a ball cap assembly 10 which includes a cap 1 1 and a protective insert 12. Cap assembly 10 is configured to have the appearance of a traditional baseball cap that is worn by players and spectators of the game. Cap assembly 10 may, in fact, include a traditional baseball cap 11 that is worn on a user's head 14. It will be understood that while a traditional baseball cap 1 1 is illustrated in the attached figures, other types of hats and caps worn by golfers and other athletes can be provided with a protective insert 12 in accordance with the present invention. In those instances, the insert will be configured to be complementary to the specific shape and features of the hat or cap in question.

Cap 11 comprises a substantially dome-shaped wall 16 which has an exterior surface 16a and an inner surface 16b (Fig. 10). Wall 16 has a bottom edge 16c which substantially circumscribes the user's head 14 when cap 1 1 is worn thereon. Wall 16 includes a front region and a peak 18 extends outwardly and forwardly away from the bottom edge 16c. Cap 1 1 has an interior diameter "D" (Fig. 10) which closely approximates the diameter of the user's head 14. Cap 11 defines an interior chamber 22 (Fig. 10) into which both insert 12 and the user's head 14 are received.

Fig. 2 illustrates insert 12 alone engaged about the user's head 14. In this figure, cap 11 has been removed for clarity. Fig. 3 illustrates insert 12 standing on its own and not engaged about a user's head. It will be noted that the insert 12 is not the traditional domed hemispherical shape that covers the entire head of the user. Instead, insert 12 is configured to protect the user's forehead, temples and areas immediately above the ears. The crown and back of the user's head do not have any portion of the insert 12 covering them, expect for the regions covered by securing straps, as will be later described herein. This configuration of insert 12 fits into a traditional cap 11 and protects the most vulnerable portions of the head but has the additional benefit of allowing air to circulate freely around the crown and back of the head.

Fig. 4 shows an exploded view of insert 12 and in this view it can be seen that insert 12 comprises a first component and a second component. The first component is an outer shell 24 and the second component is a pad 26. Pad 26 is configured to be complementary to at least a front portion of outer shell 24. Pad 26 may be adhesively engaged with shell 24 or shell 24 may be placed in a mold and the foam pad 26 is injection-molded around shell 24.

Referring to Figs. 4 and 5, outer shell 24 has an exterior surface 24a, an inner surface 24b, a top edge 24c and a bottom edge 24d. Pad 26 has an exterior surface 26a, an inner surface 26b, a top edge 26c, and a bottom edge 26d. As is evident from the figures, pad 26 is configured to be engaged with outer shell 24 such that inner surface 24b of shell 24 is disposed adjacent exterior surface 26a of pad 26. Outer shell 24 preferably is fabricated from a relatively thick, strong and rigid material such as polycarbonate plastic. Pad 26 preferably is fabricated from a high density foam that will tend to readily absorb impact forces. Preferably, pad 26 is provided to decelerate impact from a ball hit and is fabricated from a visco-elastic material or foam having a heavy density of around 0.38 g/cm3.

Shell 24 preferably is approximately 0.1 " thick and pad 26 varies in thickness from about 0.1" thick to about 0.32" thick, with the thickness being measured between the respective interior and exterior surfaces of shell 24 and pad 26. Pad 26 preferably is a molded foam pad of complex geometry and has verifying thickness in that frontal region 50 is thicker than terminal regions 54. Pad 26 tapers between frontal region 50 and terminal regions 54 so that there is a smooth transition to band 34. The tapering pad thickness also helps ensure that the overall circumference of cap 11 is kept as small as possible.

Outer shell 24 includes a frontal region 28 sized and positioned to be cover and protect the user's forehead 14a. Outer shell 24 further includes at least one but preferably a pair of temporal regions 30 (Fig. 7). Temporal region 30 is a projection which extends downwardly beyond or below bottom edge 24d of outer shell and is positioned and shaped to at least partially cover and protect one of the user's temples. Preferably, outer shell 24 includes two opposed temporal regions 30 which are opposed projections that extend outwardly and downwardly below bottom edge 24d of outer shell and each of these projections at least partially covers and projects one of the user's temples.

Preferably, each temporal region 30 is generally V-shaped and when pad 26 is engaged with shell 24, at least a portion of each V-shaped temporal region 30 will extend for a distance downwardly below bottom edge 16c of cap 16. (It will be understood that the projections that comprise temporal region 30 may be shaped differently. For instance, they may be generally semi-circular in shape.) A terminal region 32 extends rearward ly from each temporal region 30 and is configured to cover and protect a portion of the sides of the user's head immediately above the ear 14b (Fig. 1).

A band 34 extends between the opposed terminal regions 32 of shell 24 and is threaded through apertures 36 defined in each terminal region 32. Band 34 is adjustable to fit the user's head and thereby retain shell 24 and pad 26 adjacent thereto. Band 34 is semi-circular in shape and is configured to form a horizontally oriented semi-circular arch. Band 34 in conjunction with outer shell 24 fits circumferentially around the user's head 14 in a horizontal orientation.

In accordance with an aspect of cap assembly 10, at least one engagement member is provided on one or both of outer shell 24 and wall 16 to secure the insert 12 to cap 11. The engagement member includes but is not limited to one or more pin members 38, a detent 60 or hook and loop fasteners (not shown). The engagement member(s) extend outwardly and forwardly from frontal region 28 of shell 24 and toward inner surface 16b of outer wall 16 of cap 11. Alternatively, the engagement member(s) may be provided on cap 11 and extend inwardly toward shell 24.

A first engagement member is provided in the form of one or more pin members 38 provided on exterior surface 24a of shell and which extend toward and engage inner surface 16b of wall 16 adjacent frontal region 28. Pin members 38 interlockingly engage cap 11 and shell 24 together. Pin members 38 preferably are disposed in one or more rows or columns in an area of shell 24 that will directly overlay the user's forehead. Pin members 38 preferably are spaced at intervals a distance apart from each other and they preferably are of uniform diameter along their lengths. Pin members 38 frictionally engage the inner surface of outer wall 16 and thus aid in preventing cap 11 from lifting upwardly off insert 12 when the wind blows.

In accordance with yet another aspect of cap assembly 10, a first strap 40 and a second strap 42 are provided on insert 12. First strap 40 extends between opposed flanges 44 provided on terminal regions 32 of shell 24. First strap 40 is threaded through an aperture 46 (Fig. 4) in each flange. Although not illustrated herein, it will be understood that hook and loop fastener strips are provided on an exterior surface of first strap 40 proximate each free end 40a, 40b (Fig. 7) thereof and on an inner surface of each free end 40a, 40b. The hook and loop fastener strips enable the overall length of first strap 40 between flanges 44 to be adjusted. First strap 40 is semi-circular in shape and is configured to pass from side-to-side of outer shell 24 and pass over the crown of the user's head. First strap 40 thus forms a vertically oriented semi-circular arch relative to outer shell 24. First strap 40 does not engage band 34 which passes around the back of the user's head.

As best seen in Fig. 9, second strap 42 is threaded through an aperture 48 defined in frontal region 28 and extends rearwardly therefrom. Second strap 42 preferably is fixedly secured to first strap 40 approximately midway between flanges 44. Second strap 42 may be stitched to first strap 40 or be otherwise fixedly secured thereto. Preferably, second strap 42 is also fixedly secured to frontal region 28 by threaded free end 42a thereof through aperture 48 and stitching free end 42a to a portion of second strap 42. Thus, second strap 42 preferably is of a fixed length as measured between frontal region 28 and first strap 40. Although not illustrated herein, it will be understood that hook and loop fastener strips may, alternatively, be provided between free end 42a of second strap 42 and the inner surface of second strap 42 so that the overall length of second strap 42 between frontal region 28 and first strap 40 is able to be adjusted so as to more closely fit the user's head 14. Second strap is configured to be curved and pass from the front of the user's head to the crown of their head. Second strap 42 does not extend to the back of the user's head.

Thus, first strap 40 extends from proximate the user's left ear 14b to proximate the user's right ear 14b. The second strap 42 extends from proximate the top of the user's forehead to proximate the crown of the user's head. Preferably at least two of these three bands/straps 34, 40, and 42 are adjustable so that the user can change the overall dimensions of insert 12 to most closely and snugly fit their head. Preferably, each of band/straps 34, 40 and 42 is fabricated from a flexible fabric material, such as a cotton fabric, which makes them relatively easy to adjust. This helps ensure that the protective outer shell 24 and pad 26 are located in the optimum positions on the user's head to protect them from impact. Apart from apertures 36, 46, 48 outer shell 24 is substantially continuous and uninterrupted along its length and width. Protective pad 26 is complementary in shape to the rigid outer shell 24. Only the three bands/straps 34, 40 and 42 on the outer shell 24 are free of any of the padding material. Thus as shown in Fig. 4, pad 26 includes a frontal region 50, opposed temporal regions 52, and opposed terminal regions 54. Temporal regions 52 are also generally V-shaped members that extend below bottom edge 16c of wall 16. As best seen in Fig. 1 , temporal regions 52 preferably are each slightly bigger than temporal regions 30 of shell 24. Pad 26 is slightly larger in height than shell 24 so that a lip of foam padding extends above and below the upper and lower edges of shell 24. The foam lip extends around substantially the entire outer edge of shell 24 so there are no unprotected edges of the stiff outer shell 24 that could injure or cut the user if impacted by a bat or ball. Pad 26 is comprised of an impact-absorbing material and this material is substantially continuous along the entire inner surface 24b of outer shell 24. Thus, there are substantially no regions on inner surface 24b that are free of the impact- absorbing material.

As best seen in Figs. 6 and 7, substantially the entire bottom edge 24d of shell

24 lies generally along a plane "P". Similarly, substantially the entire bottom edge 26c of liner 26 is disposed generally along a plane "P1 ". Two sections of bottom edge 24d and bottom edge 26d are not aligned along planes "P" and "ΡΓ. These two sections are located on projections 30 which extend outwardly for a distance below planes "P" and "P1". The projections 30 comprise temporal regions on cap assembly 10 which are provided to extend over and cover the temples of the user wearing cap assembly 10. It should be noted that bottom edge 16c of cap 16 is disposed either generally aligned with plane "P1" or a distance downwardly below plane "P1". Consequently, when the cap assembly 10 is worn, as illustrated in Fig.1 , substantially little to none of the bottom edge 24d of outer shell 24 or the bottom edge 26d of liner is visible. The only portions of the insert that are visible are the two temporal regions or projections 30 and possibly a small section of the terminal regions 54 of the insert.

The upper edge 26c of pad 26 is configured to have a pair of opposed depressions 56 (Fig. 4) formed therein to accommodate flanges 44. Upper edge 26c further defines a recess 58 in the central region of shell 24 to accommodate part of the second strap 42 which is threaded through aperture 46 in frontal region 28 of shell 24. Pad 26 also includes a second engagement member in the form of the substantially horizontal detent 60 which extends outwardly from a bottom edge of frontal region 50 of liner 26. Detent 60 extends for a distance beyond frontal region 28 of shell 24 and toward the inner surface of outer wall 16 of cap 1 1. As best seen in Fig. 10, detent 60 extends for a short distance below peak 18 of cap 11. The weight of peak 18 on detent 60 aids in keeping insert 12 engaged on the user's head, particularly on the front of the user's head. Detent 60 also tends to prevent cap 11 from sliding downwardly on the user's head 14 and thus ensures that frontal regions 28, 50 are properly situated on the user's head to protect the forehead, temples and regions above the ears against impact.

Cap assembly 10 is substantially free of any protective components disposed on the exterior surface 16a of wall 16. In other words, the exterior surface of cap assembly 10 has the appearance of a traditional baseball cap that is free of any protective elements. Only small parts of temporal regions 30, 52 are visible as these regions extend downwardly below bottom edge 16c of cap 1 1 to protect the vulnerable temples of the user.

Cap assembly 10 is specifically designed for different head sizes using accurate human head CAD models in increments of two head sizes. This sizing is due at least partially to the fairly rigid and unforgiving outer shell 24 which is very specific to head size in order to keep the overall thickness of insert 12 thin enough so that cap 1 1 selected for the assembly 10 is only required to be a slightly larger hat size than normally would be worn by the user. The overall cap size for a user will tend to be around two or three larger hat sizes than would be the case if a regular baseball cap was to be worn. The user adjusts one or more of the bands/straps 34, 40 and 42 to ensure a snug fit for the insert 12 on the user's head 14.

The insert 12 provides significant protection from balls moving toward a user's forehead and/or sides of their head 14. This is due to the fact that most users, particularly ball players, are positioned to directly face the ball with either their foreheads or the sides of their head back to slightly rear of their ears. Furthermore, most users will instinctively turn their head to avoid a direct face hit and thereby bring their temples into a position where they could be struck by a flying ball. A ball hit in baseball is different than in football where the head is the projectile and cushioning in the football helmet has some distance to decelerate the brain. Cap assembly 10 is provided to protect against a ball hit where the impact from a ball hit must dissipate over a wider area where there is some compression of the underlying protective padding 26.

In the foregoing description, certain terms have been used for brevity, clearness, and understanding. No unnecessary limitations are to be implied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed.

Moreover, the description and illustration of the preferred embodiment of the invention are an example and the invention is not limited to the exact details shown or described.