Cap and sweatband having cooling and sweat wicking features

Abstract

The present invention is an article of headwear that is conformable so as to accommodate a wide range of head sizes comprised of at least a crown portion that substantially covers the head of the wearer. Proximate the lowest edge of the crown portion is a sweatband or headband permanently affixed thereto that is stretchable in all directions, not just vertically and horizontally. The band is comprised of elastic threads woven into a diamond pattern so that it is capable of stretching and returning substantially to its original shape. In an alternative embodiment of the sweatband, the sweatband comprises a base layer of a flexible material with a plurality of longitudinal bands of fibers with wicking, odor reducing and antibacterial properties superimposed upon the base material of the sweatband.

Claims

1. An expansible cap comprising: a crown portion having a front and a back and a peripheral edge portion; an internal sweatband having first and second abutting ends circumscribing the interior of said expansible cap; wherein the sweatband includes a base layer having a longitudinal length and an upper longitudinal edge and a lower longitudinal edge with a cross-sectional width, therebetween, the base layer defining an inner surface for contacting a user's skin and an outer surface at an opposing side of the inner surface; a plurality of longitudinal bands having widths of fibrous material, attached to the base layer, each of the longitudinal bands including a plurality of yarn strands arranged consecutively along the cross-sectional width of the sweatband; wherein the plurality of longitudinal bands are disposed between the upper longitudinal edge of the base layer and the lower longitudinal edge of the base layer, adjacent longitudinal bands being separated by a uniform gap width; wherein the yarn strands of at least one of the plurality of longitudinal bands is composed of wicking fibers; and wherein the yarn strands of at least one of the plurality of longitudinal bands is composed of fibers containing coffee residue; wherein the yarn strands of each of the longitudinal bands is disposed on the base layer to project beyond the outer surface.

2. The expansible cap of claim 1, wherein the base layer is composed of an elastic material.

3. The expansible cap of claim 1, wherein a margin of 3 mm is maintained between the upper longitudinal edge of the base layer and a first of the longitudinal bands.

4. The expansible cap of claim 1, wherein a margin of 3 mm is maintained between the lower longitudinal edge of the base layer and a last of the longitudinal bands.

5. The expansible cap of claim 1, wherein the at least one of the plurality of longitudinal bands having yarn strands composed of wicking fibers has a cross-sectional width of 4 mm with about five (5) yarns of wicking fibers thereacross.

6. The expansible cap of claim 1, wherein the at least one of the plurality of longitudinal bands having yarn strands composed of fibers containing coffee residue has a cross-sectional width of 4.5 mm with about five (5) yarns of fibers containing coffee residue.

7. The expansible cap of claim 1, wherein the wicking fibers extend to a height of approximately 2.4 mm from the base layer, and the fibers containing coffee residue extend to a height of approximately 2.3 mm from the base layer.

8. The expansible cap of claim 1, wherein a gap width of 1 mm is maintained between each of the plurality of longitudinal bands, regardless of whether the yarn strands of the longitudinal bands are composed of wicking fibers or fibers containing coffee residue.

9. The expansible cap of claim 1, wherein the sweatband includes a pocket on the interior of the sweatband, the pocket being configured to hold a monetary bill, house key or like sized item.

10. The expansible cap of claim 1, further comprising a visor having a front and a back peripheral edge, the back peripheral edge being affixed to the crown portion proximate the front peripheral edge, whereby the sweatband is also affixed to the portion of the visor proximate the back peripheral edge of the visor where the crown portion is attached to the visor.

11. The expansible cap of claim 1, wherein each of the yarn strands composed of wicking fibers forms a FIG. 8 configuration extending out from the base layer.

12. The expansible cap of claim 1, wherein each of the yarn strands composed of fibers containing coffee residue forms a FIG. 8 configuration extending out from the base layer.

13. The expansible cap of claim 1, wherein the yarn strands of each of the longitudinal bands are angled relative to the cross-sectional width of the sweatband.

14. The expansible cap of claim 1, wherein at least one of the longitudinal bands having yarn strands composed of wicking fibers has a first cross-sectional width and at least one of the longitudinal bands having yarn strands composed of fibers containing coffee residue has a second cross-sectional width, the first and second cross-sectional width being unequal.

15. The expansible cap of claim 1, wherein the yarn strands composed of wicking fibers have a first height from the base layer and the yarn strands composed of fibers containing coffee residue fibers have a second height from the base layer, the first and second heights being unequal.

16. An expansible cap comprising: a crown portion having a front and a back and a peripheral edge portion; an internal sweatband having first and second abutting ends circumscribing the interior of said expansible cap; wherein the sweatband includes a base layer having a longitudinal length and an upper longitudinal edge and a lower longitudinal edge with a cross-sectional width, therebetween; a plurality of longitudinal bands having widths of fibrous material, attached to the base layer; wherein the plurality of longitudinal bands are disposed between the upper longitudinal edge of the base layer and the lower longitudinal edge of the base layer; wherein the yarn strands of at least one of the plurality of longitudinal bands is composed of wicking fibers; wherein the yarn strands of at least one of the plurality of longitudinal bands is composed of fibers containing coffee residue; and wherein at least one of the of longitudinal bands having yarn strands composed of wicking fibers has a cross-sectional width of 4 mm with five (5) yarn strands of wicking fiber thereacross; and wherein at least one of the longitudinal bands having yarn strands composed of fibers containing coffee residue has a cross-sectional width of 4.5 mm with five (5) yarn strands of fibers containing coffee residue thereacross; and, wherein the yard strands composed of wicking fibers and the yard strands composed of fibers containing coffee residue are perpendicularly directed relative to the base layer; and, wherein the height of the wicking fibers from the base layer is about 2.4 mm and the height of the fibers containing coffee residue are about 2.3 mm from the base layer.

17. The expansible cap of claim 16, wherein each of the yarn strands composed of wicking fibers forms a FIG. 8 configuration extending out from the base layer.

18. The expansible cap of claim 16, wherein each of the yarn strands composed of fibers containing coffee residue forms a FIG. 8 configuration extending out from the base layer.

19. The expansible cap of claim 16, wherein the yarn strands of each of the longitudinal bands are angled relative to the cross-sectional width of the sweatband.

20. The expansible cap of claim 16, wherein the base layer defines an inner surface for contacting a user's skin and an outer surface at an opposing side of the inner surface, the yarn strands of each of the longitudinal bands being disposed on the base layer to project beyond the outer surface.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) A detailed description of the invention will be made with reference to the accompanying drawings wherein like numerals of reference depict like elements throughout and in which:

(2) FIG. 1 is a perspective view of a cap in accordance with a preferred embodiment of the present invention;

(3) FIG. 2 is a schematic, exploded view of a portion of one embodimet of the sweatband of the invention illustrating the diamond configured weave pattern;

(4) FIG. 3 is a schematic, enlarged view of the embodiment of the diamond woven sweatband of FIG. 2 illustrating how, in stretched of conforming configuration, the sweatband stretches in a plurality of directions;

(5) FIG. 4 is a cross sectioned view of a cap of the invention illustrating the label affixed over the abutting ends of the sweatband of a cap;

(6) FIG. 5 is a perspective view of an additional exemplary embodiment of the sweatband of the present invention, comprised of longitudinal bands of wicking yarns and coffee yarns sewn or otherwise secured to a base layer;

(7) FIG. 6 is an enlarged view of a portion of the sweatbands of FIG. 5, showing an exemplary pattern of the longitudinal bands of wicking yarns and coffee yarns of the alternative embodiment of the sweatband of the present invention;

(8) FIG. 7 is a cross-sectional view of the sweatband of the present invention taken along the line 7-7 of FIG. 6, showing the pattern and spacing of bands of wicking and coffee yarns across the width of the sweatband, as used in the present invention; and

(9) FIG. 8 is an enlarged view of a portion of the sweatband as shown in FIG. 7, depicting individual wicking and coffee yarns.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(10) The detailed description set forth below in connection with the appended drawings is intended as a description of presently-preferred embodiments of the invention and is not intended to represent the only forms in which the present invention may be constructed or utilized. The description sets forth the functions and the sequence of steps for constructing and utilizing the invention in connection with the illustrated embodiments. However, it is to be understood that other applications of the cap of the invention will be readily apparent to those of ordinary skill in the art.

(11) In the following descriptions of the invention, terms such as top, bottom, first end and second end, horizontal, longitudinal, and the like are used herein merely for ease of description and refer to the orientation of the components shown its the figures. Further, the figures herein are not drawn to scale and should be considered to present an illustration of various embodiments of the present invention. Some features of the invention may have been distorted or enlarged to facilitate an understanding of the invention.

(12) Generally, the present invention may be briefly described as follows. Referring first to FIG. 1, a cap using the features and advantages of the present invention is shown. It should be understood that while a baseball cap is shown, the invention applies all headgear that has a crown portion covering either all or part of the scalp portion of the head. As such, the invenion applies to hats with visors, visors without total scalp covering, baseball caps, etc.

(13) The baseball cap 10 comprises a crown portion 12 fabricated so that it substantially fits over the crown of a wearer's head. In a preferred embodiment the crown portion has a lower peripheral, circumferential edge 14 and a visor 16 extending from the front peripheral edge of the crown portion 12 so as to substantially shade the face and/or the eye area of the person wearing the cap 10 when the cap is properly placed upon the head.

(14) A headband or sweatband 18 extends around the entire peripheral opening 14 of the crown portion 12 and is affixed to the crown portion 12 such that it is fully located within the crown portion 12 as shown in FIG. 1.

(15) The crown portion 12 may be fabricated from several gores, which is a preferred embodiment of the present invention, comprising gores 20a, 20b, 20c, 20e, and 20f that are made of either synthetic or natural materials, such as polyesters, cotton, woven and non-woven material, felt, cotton with spandex, and other similar stretchable or non-stretchable materials. In addition, the gores may be made entirely or partially out of material that allows airflow to the scalp of the wearer. The number of gores 20 comprising the crown portion is dependent on the size of the final crown 12, the size of the gore, and the tensile strength of the material being used. In an embodiment, the gores contain one or more air holes 22 to allow the passage of air and moisture through the crown portion 12. In an embodiment, seam tape 24 or other material is used to cover the interior surfaces of the crown 12 where the gores 20 are affixed to each other to hide the seams created by attaching the gores to each other. In an embodiment of the present invention, a button 23 is placed upon the spot where the gores 20 converge at the top of the crown 12.

(16) In the figures, the headband 18 of the present invention is shown. Headband 18 is comprised of an elongated woven band of elastic yarns wherein the yarns are woven in a diamond or diagonal pattern 19 as shown in the drawing. The diamond or diagonal pattern of the weave of the band allows it to be repeatedly stretched in a circumferential direction around the head of the wearer and repeatedly to substantially return to its original unstretched position, while still stretching as showing in FIG. 3 for conformability and comfort. The length of the woven band 18 is determined by the maximum size of the inner peripheral edge 14 of cap 10 such that in its fully extended position, the band it is not larger than the maximum size of the inner peripheral edge of cap 20. In one embodiment, the band is approximately 3.3 cm in width by 60 cm in length.

(17) As those of ordinary skill in the art will recognize, the headband 18 is affixed to the peripheral edge of the crown portion of the cap and the peripheral edge of the visor 16 of the cap as shown in FIG. 1 by sewing. It should be noted that other methods of securing the headband 18 to the crown portion 12 and to the visor 16 are considered to be within the scope of the present invention. Also when the sweatband or headband is affixed to the peripheral edge 14 of crown 12, the ends 42, 44 of the headband 18 are secured together and may be hidden or overlaid by label 48 so as to prevent binding or discomfort caused by the seam. In a preferred embodiment, the seam is located at the base of the head proximate the neck of the wearer.

(18) In one embodiment, the label 48 is constructed so as to form a pocket 47 of a size to accommodate the insertion of a human finger wherein secret retention of a monetary bill or other item may be secretly stored.

(19) The pocket 47 may also be used as a means of hanging the cap 10 on a hook or other securing means.

(20) The diamond or diagonal weave on the sweatband or headband 18 in the relaxed or unconfirmed state is capable of stretching in all directions as shown in FIG. 3 and thus can accommodate a wide range of head sizes in comfort.

Example

(21) A baseball cap is fabricated of fabric gores with a stiff visor. A sweatband or headband of approximately 1.35 to 1.5 cm in width and about 16 to 25 cm in length, having been fabricated using threads that, are woven in an intersecting, diagonal pattern such that in the relaxed state, the threads form a plurality of diamonds in side-by-side configuration.

(22) By of the example and not limitation, the material contents of the band (per 1=23.9 g/yd.) is as follows: Vertical yarns: 13.7 g, 57%; Horizontal yarns: 3.6 g, 15%; Elastic materials (spandex): 6.6 g, 28%; Thickness of yarn: 300D Number of yarns needed: Vertical: 154 polyester yarns and 40 spandex yarns; Horizontal: 1 combined yarn with polyester and spandex as one yarn.

(23) The weaving is specially designed to weave diagonally instead of traditional rectangular weaving.

Detailed Description of the Alternative Sweatband Embodiment

(24) The alternative eembodiment of the sweatband of the present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. The invention may, however, may be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein. Rather these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art, Like numbers refer to like elements throughout.

(25) With reference to FIGS. 5-8, the present invention sweatband 100 provides a sweat absorbing band constructed of a combination of elements. The innermost or base layer 102 of the sweatband 100 comprises a longitudinal length 103 having an upper longitudinal edge 104 and a lower longitudinal edge 105 defining a cross-sectional width 136 therebetween. The base layer is capable of stretching both axially and transversely and will typically be made from a flexible polyester fabric which allows the sweatband to achieve a snug fit about a user's head. Sewn into the base layer 102 of the sweatband 100 are a plurality of longitudinal bands 106 comprised of fibers having specific properties different from that of the base layer 102.

(26) Generally, throughout this application the terms sweatband and headband will be used interchangeably. It should be understood however, that a sweatband, in addition to be being a head band, could be a wrist band (popular with tennis players) or even an arm band or an ankle band, or other like band.

(27) In the exemplary embodiment of the present invention sweatband 100, the plurality of longitudinal bands of fibers 106 comprises six specific bands of longitudinal fibers 108, 110, 112, 114, 116 and 118. (See FIG. 6.) The upper two longitudinal bands of fibers, from the perspective of FIG. 6, are bands 108 and 110. Longitudinal bands 108 and 110 are wicking bands which are made from relatively loosely spaced polyester yarn, call wicking yarn 120. (See FIG. 7.) Each strand of wicking yarn 120 is fabricated in a FIG. 8 configuration and each such strand of wicking yarn 120 extends perpendicularly from the base layer 102. Along the cross-sectional width 136 of the base layer 102, the yarns of the bands 108 and 110 of wicking yarn 120, are spaced in sets 126, wherein each set 126 comprises five (5) yarns per 4 mm of cross-sectional width with a gap width 132 of one (1) mm of width, between each set 126 of five (5) yarns.

(28) The above pattern of one set 126 of wicking yarns comprising 5 yarns per 4 mm of cross-sectional width with a gap width 132 of 1 mm between the next set 126 of wicking yarns 120 is repeated between cross-sectional lengths of wicking yarn bands.

(29) As will be discussed below, the spacing of sets 126 of wicking yarns and of sets 128 of coffee yarns differs, but in all cases a gap width 132 of 1 mm with is maintained between each band (108, 110, 112, 114, 116 and 118) of wicking and/or coffee yarns.

(30) As discussed each individual wicking yarn 120 extends perpendicularly from the polyester base layer 102. Experimentation has shown that a height 124 of about 2.4 mm for the wicking yarn 120 from the base layer 102 to the top of the yarn to be well suited for wicking sweat from the base layer 102 to the top of wicking yarn where convection cooling is believed to occur.

(31) In the exemplary embodiment from the perspective of FIG. 6, below the first two upper bands 108 and 110 of wicking yarn, are two intermediate bands 112 and 114 of coffee yarn. Coffee yarn is, as the name suggests, a type of yarn made from the residue of coffee, i.e. coffee grounds. Coffee yarn is made by incorporating coffee residue into a polyester base material from which the yarn is drawn. Coffee yarn is believed to have odor reducing and antibacterial properties which makes it a useful material for use in sweatbands. Coffee yarn is available from the Magictex Apparel Corporation located in Taipei, Taiwan. The chemical composition and production process for producing coffee yarns is disclosed in U.S. Pat. No. 8,834,753 entitled Process of Making Yarns with Coffee Residue, which issued to Hung, et al. on Sept. 16, 2014.

(32) Similar to the wicking yarn 120, each strand of the coffee yarn 130 extends perpendicularly from the base layer 102 in a FIG. 8 configuration. Along the cross-sectional width 136 (see FIG. 6) of the base layer 102, each of the bands 112 and 114 of coffee yarn are spaced in sets 128 of five (5) yarns per 4.5 mm of cross-sectional width with a 1 mm gap width between each set of the sets 128 of five (5) yarns.

(33) As shown in the exemplary embodiment, although the cross-sectional width of each set of wicking and coffee yarns differs, i.e. 4 mm for each set 126 of wicking yarns and 4.5 mm for each set 128 of coffee yarns, the gap width 132 between the adjacent bands of yarns is maintained at one (1) mm across the entire cross-sectional width 136 of the base layer 102, regardless of yarn type.

(34) Similarly to the wicking yarns 120 , each individual coffee yarn 130 extends perpendicularly from the base layer 102. The inventor's experience has suggested that a height 124 (see FIG. 8) for the coffee yarn of about 2.3 mm from the base layer 102 to the top of the yarn to be well suited for making use of the yarn's anti-odor and anti-bacterial functions.

(35) The bottom two rows, from the perspective of FIG. 6, of longitudinal wicking bands 116 and 118 sewn into the base layer 102 are identical in all respects to the first two rows 108 and 110 of wicking bands described above. With reference to FIG. 7, in the exemplary embodiment, an edge width 134 of about 3 mm is maintained between upper and lower longitudinal edges of the base layer 120 and edge of the nearest longitudinal band of wicking and/or coffee fiber.

(36) In further alternative embodiments, the number and placement of the wicking and coffee bands of the sweatband may by changed depending upon the particular sport for which the sweatbands will be used and for the specific purpose that the sweatbands will be used. The two wicking bands, two coffee bands and two wicking bands construction of the exemplary embodiment described above is believed to be well suited for use as a headband. However, in a wrist band application, other arrangements such as one wicking band, one coffee band and another wicking band may also be suitable. Yet other applications may use other combinations of fiber bands.

(37) The inventors of the sweatband of the present invention believe that the band operates substantially more efficiently than those of the prior art because during vigorous athletic activity it is believed that a pressure differential arises between the base of the sweatband and the outermost fibers of the wicking and coffee bands. A region of higher than ambient pressure is believed to be created at the base of the sweatband which is in contact with the wearer's skin. During vigorous workouts, a wearer's skin tends to get hot and produce sweat, the combination heat and sweat production is believed to locally increase pressure at the base of sweatband above that of the ambient conditions. As a result, sweat is wicked by the wicking and coffee fibers to the tops of the fibers which are believed to be at near ambient conditions, i.e. are slightly cooler and at slightly less pressure than the conditions at the base of the sweatband.

(38) The foregoing detailed description and appended drawings are intended as a description of the presently preferred embodiment of the invention and are not intended to represent the only forms in which the present invention may be constructed and/or utilized, Those skilled in the art will understand that modifications and alternative embodiments of the present invention which do not depart from the spirit and scope of the foregoing specification and drawings, and of the claims appended below are possible and practical. It is intended that the claims cover all such modifications and alternative embodiments.