Removable (and optionally washable) hat insert for absorbing perspiration

Abstract

The challenge of protecting caps from excess perspiration is solved by providing a hat liner comprising: (a) a first portion including a plurality of tabs separated by one or more gaps, the first portion dimensioned so that at least a part of it fits between, and is held by, the sweatband of a cap and one or more front panels of a hat; and (b) a second portion, directly or indirectly joined with the first portion along a length, and including at least one moisture absorbing layer. The second portion may further include at least one moisture wicking layer. The first portion may include at least three tabs defined and separated by at least two gaps. At least some of the two gaps may have a wider open end and a narrower closed end. Each of the plurality of tabs in the first portion may be provided with a plurality of lateral ridges. The second portion may be indirectly joined with the first portion via the hinge portion. The hinge portion is provided with a plurality of lateral slits.

Claims

1. A cap liner comprising: a) a first portion including a plurality of tabs separated by one or more gaps, the first portion dimensioned so that at least a part of the first portion is configured to fit between, and be held by, a sweatband of a cap and one or more front panels of the cap; b) a second portion including at least one moisture absorbing layer; and c) a hinge portion, wherein the second portion is indirectly joined with the first portion via the hinge portion, wherein the hinge portion is provided with a plurality of lateral slits, wherein each of the plurality of tabs in the first portion is provided with a plurality of lateral ridges, wherein the plurality of tabs provided in the first portion includes two outer tabs and at least one inner tab, wherein the hinge includes two outer sections, each adjacent to a respective one of the two outer tabs, and at least one inner section, each adjacent to a respective one of the at least one inner tab, wherein the plurality of slits includes a plurality of outer slits each having a first length and a plurality of inner slits each having a second length, wherein each outer section of the hinge includes a respective outer slit of the plurality of outer slits, wherein each inner section of the hinge includes two respective inner slits of the plurality of inner slits, separated by a narrow span, and wherein the second length is shorter than the first length.

2. The cap liner of claim 1 wherein the second portion further includes at least one moisture wicking layer.

3. The cap liner of claim 1 wherein the first portion has a length of between about 8″ and 10½″.

4. The cap liner of claim 1 wherein the second portion has a length of between about 8″ and 10½″.

5. The cap liner of claim 1 wherein the first portion has a width which is less than a width of the second portion.

6. The cap liner of claim 1 wherein the plurality of tabs of the first portion include at least three tabs, wherein the one or more gaps includes at least two gaps, and wherein the at least three tabs are defined and separated by the at least two gaps.

7. The cap liner of claim 6 wherein at least some of the at least two gaps have a wider first end and a narrower second end.

8. The cap liner of claim 6 wherein at least some of the at least two gaps are V-shaped.

9. The cap liner of claim 1 wherein the second portion includes a layer of compression molded, closed-cell foam.

10. The cap liner of claim 9 wherein the second portion is about 1 mm thick.

11. The cap liner of claim 1 wherein each of the plurality of lateral ridges is compression molded, closed-cell foam.

12. The cap liner of claim 1 wherein each of the plurality of lateral ridges is about 0.5 mm thick.

13. A combination comprising: a) a cap including a bill, a sweatband, and a plurality of panels, at least some of the plurality of panels arranged adjacent to the bill and defining front panels; and b) a cap liner including i) a first portion including a plurality of tabs separated by one or more gaps, the first portion dimensioned so that at least a part of the first portion fits between, and is held by, the sweatband of the cap and one or more of the front panels of the cap; ii) a second portion including at least one moisture absorbing layer, and iii) a hinge portion, wherein the second portion is indirectly joined with the first portion via the hinge portion, wherein the hinge portion is provided with a plurality of lateral slits, wherein each of the plurality of tabs in the first portion is provided with a plurality of lateral ridges, wherein the plurality of tabs provided in the first portion includes two outer tabs and at least one inner tab, wherein the hinge includes two outer sections, each adjacent to a respective one of the two outer tabs, and at least one inner section, each adjacent to a respective one of the at least one inner tab, wherein the plurality of slits includes a plurality of outer slits each having a first length and a plurality of inner slits each having a second length, wherein each outer section of the hinge includes a respective outer slit of the plurality of outer slits, wherein each inner section of the hinge includes two respective inner slits of the plurality of inner slits, separated by a narrow span, and wherein the second length is shorter than the first length.

14. A cap liner comprising: a) a first portion including a plurality of tabs separated by one or more gaps, the first portion dimensioned so that at least a part of the first portion is configured to fit between, and be held by, a sweatband of a cap and one or more front panels of the cap, wherein the plurality of tabs provided in the first portion includes two outer tabs and at least one inner tab; b) a second portion including at least one moisture absorbing layer; and c) a hinge portion through which the second portion is indirectly joined with the first portion, the hinge portion including 1) two outer sections, each being adjacent to a respective one of the two outer tabs, and each including a first plurality of lateral slits, each of the first of the plurality of lateral slits having a first length, and 2) at least one inner section, each being adjacent to a respective one of the at least one inner tab, and each including at least two lateral slits, each of the at least two lateral slits having a second length and being separated from an adjacent one of the at least two of the plurality of lateral slits by a narrow span, wherein the second length is shorter than the first length.

Description

§ 3. BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIGS. 1A-1D illustrate small, medium, large, and universal sized liners consistent with the present description. FIG. 1E illustrates a universal sized liner provided with slits at a hinge.

(2) FIGS. 2A-2C are cross-sectional views of alternative designs of first and second portions of a liner consistent with the present description.

(3) FIGS. 3A and 3B are alternative front perspective semi-transparent view of a hat liner consistent with the present description provided within a cap. FIG. 3C is a rear perspective semi-transparent view of a hat liner consistent with the present description, such as those in FIGS. 3A and 3B, provided within a cap.

(4) FIGS. 4A and 4B are cross-sectional views of alternative liners having a first portion and a multilayer (laminated) second portion.

(5) FIGS. 5A and 5B are cross-sectional views showing how alternative liners consistent with present description can fit between the panels and sweatband of a cap.

(6) FIGS. 6A and 6B are cross-sectional views of alternative designs of first and second portions of a liner, and FIG. 6C is a plan view of a liner, provided with rubber (e.g., silicon, compression molded closed foam, etc.) dots and/or ridges, while FIG. 6D is a plan view of a liner provided with (e.g., silicon, compression molded closed cell foam, etc.) lateral ridges, consistent with the present description.

§ 4. DETAILED DESCRIPTION

(7) FIGS. 1A-1D are small 100A, medium 100B, large 100C, and universal 100D sized liners consistent with the present description. FIG. 1E illustrate a universal sized liner 100E provided with slits 135a-135f In each case, the liner includes first portion 110 and a second portion 120. The first portion 110 and second portion 120 are intended to be hinged with respect to each other so that they may be folded together, or almost together. Alternatively, as shown in the cross-sectional view of FIG. 2A, the first portion 110 and second portion 120 may be joined at one end and form very small angle θ (where θ<ten degrees and preferably less than five degrees). Alternatively, as shown in the cross-sectional view of FIG. 2B, the first portion 110 and second portion 120 may be joined at one end via a third (hinge) portion 130.

(8) As shown in FIG. 1E, the hinge portion 130 may be provided with a plurality of lateral slits 135a-135f. Each of the lateral slits is about (or roughly) 1/32″ wide. Each of the longer lateral slits 135a and 135f is about (or roughly) 1.75″ long, while each of the shorter lateral slits 135b-135e is about (or roughly) 1.0″ long. The lateral slits 135a-135f help the liner to fold and fit into a hat. Holes can be provided in addition to, or instead of, the lateral slits. However, providing holes instead of lateral slits makes it more difficult to remove waste material during manufacturing. Providing two shorter lateral slits (e.g., 135b and 135c, or 135d and 135e) instead of a longer lateral slit helps with fitting as the spans 136a and 136b help prevent the center portions of otherwise longer lateral slits from separating excessively when inserted into a hat.

(9) Referring back to FIGS. 1A-1E, the first portion 110 may include a plurality of tabs 112, each of which is separated by a V-shaped gap 114. Although the number of tabs (N) is shown as four in each of FIGS. 1A-1E, the number can range from as little as one (1) tab to as many of eight (8) tabs. Fewer, longer, tabs may be used if the first portion 110 is made from a more flexible material, and/or with a thickness that imparts more flexibility. If the first portion 110 is made from a less flexible material and/or with a thickness that imparts less flexibility, a greater number of shorter tabs may be used. The number of V-shaped gaps 114 is one less (N−1) than the number (N) of tabs 112. (Note that if there is only one tab, there will be no gaps or slits.) Although the gaps 114 are depicted as V-shaped, this is not necessary. However, the gaps 114 should narrow from the open end to the closed end. Further, although the gaps are shown as extending from one edge of the first portion 110 to the opposite edge, the gaps need not extend so far. In some example embodiments consistent with the present description, a combination of a gap and a slit (not shown) is provided in the first portion. In such example embodiments, the gap narrows to the slit, and the slit may extend to the edge of the first portion 110. Referring to FIGS. 3A and 3B, the gaps 114 and/or slits (not shown) are provided to facilitate the insertion of the first portion 110 in the space between panel(s) and the sweatband of the cap.

(10) The first portion 110 may be made from a flexible plastic sheet or laminate, such as polyethylene terephthalate (PETE or PET), high-density polyethylene (HDPE), polyvinyl chloride (PVC), low-density polyethylene (LDPE), or polypropylene (PP) for example. Alternatively, the first portion 110 may include (for example, as one or more layers, and/or be impregnated with) such a plastic(s). As shown in FIGS. 3A and 3B, the first portion 110 is intended to fit between the sweatband and one or more panels of the cap. For example, the first portion may extend entirely across two front panels and partially extend into two side panels.

(11) The second portion 120 may be made from a moisture absorbing material, such as fabric, neoprene, neoprene, terry cloth, microfiber, cotton polymer, cotton, polyester, a blend of one or more of the preceding, and the like. The second portion may have multiple layers to wick and/or hold moisture. Referring back to FIG. 2A the first portion 110 and a layer of the second portion 120 may be made from the same material (e.g., sheet plastic). The material may be formed from a single (e.g., compression molded closed cell foam) sheet and bent, or made from one or two sheets and fused together, or otherwise joined (e.g., stitched, adhered, etc.). If the second portion 120 has a layer formed from the same material as the first portion, additional layers should be provided between any non-moisture absorbing layers and the cap wearer's forehead. (See FIG. 3C.) The top edge of the second portion 120 should be straight, while the bottom edge of the second portion 120 may be straight or slightly curved as shown. Any moisture absorbing layer of the second portion should be between 0.5 mm and 5.0 mm thick. The first portion 110 may be the same material as the second portion, but without closed cell foam in between fabrics that are compression molded together and glued (which allows the two materials to bond).

(12) The second portion 120 may be provided as a single material, or multi-layer laminate. One or more layers may be formed from non-woven materials including, for example, non-woven wood, wood pulp fibers, paper or non-woven absorbent polymeric fibers, or the like. One or more layers may be made from a perforated non-woven material (for example, spunlace) One or more of the layers may be a moisture-barrier layer to prevent sweat from the liner from wicking to the sweatband, panels, and/or visor of the cap.

(13) The first layer 110 and/or the second layer 120 made from, include a layer of, or be impregnated or otherwise provided with, a rubber, such as, for example, natural/isoprene rubber, ethylene propylene diene (EPDM), nitrile rubber (NBR), styrene butadiene rubber (SBR), silicone rubber, butyl rubber, polybutadiene, and the like. Referring to FIGS. 4A and 5A, in one example embodiment consistent with the present description, rubber (for example, provided as ridges or dots) may be provided on one or both sides of portion 110, and/or on the inside surface of portion 120. For example, silicon dots or ridges may be used to help hold the hat liner in place once inserted into the cap. The amount, texture and location of such rubber should be chosen to hold the hat liner in place, yet allow the hat liner to be inserted into the cap without too much flexing and/or sticking when inserting it. FIGS. 6A and 6B are cross-sectional views of alternative designs of first and second portions of a liner (Recall, e.g., FIGS. 2A and 2B.) provided with rubber (e.g., silicon) dots and/or ridges (610a, 610b, 620a and/or 620b) consistent with the present description. FIG. 6C is a plan view of a liner in which the tabs 112 are provided (on one or both sides) with dots and the second portion 120 is provided with ridges. FIGS. 3B, 4B, 5B and 6D are embodiments of a liner in which each of the tabs 112 is provided with a plurality of (e.g., three) lateral ridges 118. However, my invention may include any combination of rubber (or compression molded) dots and/or ridges on one or both sides of portion 110, and/or on the inside surface of portion 120. Referring to FIGS. 2C, 4B and 5B, the padding 120b may be about (or roughly) 1 mm thick, while the lateral ridges 118 may be about (or roughly) 0.5 mm thick. Both the padding 120b and the lateral ridges 118 may be formed from compression molded, closed-cell foam.

(14) FIGS. 1A-1E provide dimensions (in units of inches) of small 100A, medium 100B, large 100C, and universal 100D sized liners, respectively. One or more of these dimensions may be adjusted (for example within ±10 percent). In alternative embodiments consistent with the present description, the widths of the first portion 110 and second portion 120 may be substantially greater than the 1″ and 1⅜″ dimensions shown. However, the width of the first portion 110 should be less than (for example, ⅜″±10 percent less than) the width of the second portion 120.

(15) FIG. 4A is a cross-sectional view of a liner in which the first portion 110 and a layer 120a of a second portion 120 are made from the same material (e.g., a bent and/or fused plastic sheet), and in which the second portion 120 has one or more additional layers 120b (e.g., to transfer or wick perspiration and/or absorb perspiration). FIG. 4B is similar to FIG. 4A, but the first portion 110 is provided with lateral ridges 118.

(16) FIG. 5A is a cross-sectional view showing how a liner consistent with present description can fit between the panels 510 and sweatband 520 of a cap. As shown, the first portion 110 is accommodated (and held) in a space between the panel 510 and the sweatband 520. The second portion 120 covers (or substantially, but not totally, covers) the sweatband 520. FIG. 5B is similar to FIG. 5A, but the first portion 110 is provided with lateral ridges 118.

(17) My invention is not limited to the exact materials and dimensions described. The term “about” when referencing a dimension is intended to be the dimension+/−10 percent. The term “roughly” when referencing a dimension is intended to be the dimension+/−20 percent. My invention is intended to include about (or roughly) any dimension(s) shown on the drawings.