INSERT FOR A HAT

Abstract

A bump cap foam insert for a hat that uses tab and slot structures to form the insert in to a generally conical shape to fit into a hat. The foam insert is constructed by the use of vented radial extensions that extend from a common center and that have a density of about 4 pounds per cubic foot, a thickness of about 0.16″ and a tensile strength of about 90 psi.

Claims

1. A foam insert for a hat comprising: a first elongated radial extension having a left perimeter and right perimeter, the first elongated radial extension defining a slot on the left perimeter and the first elongated radial extension defining a slot on the right perimeter; a second elongated radial extension having a left perimeter and a right perimeter, the second elongated radial extension being located left of and adjacent to the first elongated radial extension, the second elongated radial extension having a tab located on the right perimeter, the tab shaped to lock into the slot on the left perimeter of the first elongated radial extension. a third elongated radial extension having a left perimeter and a right perimeter, the third elongated radial extension being located right of and adjacent to the first elongated radial extension, the third elongated radial extension having a tab located on the left perimeter, the tab configured to lock into the slot on the right perimeter of the first elongated radial extension; and, a fourth elongated radial extension have a bottom perimeter, the bottom perimeter defining an arch, the fourth radial extension have a length that is less than the length of the first elongated radial extension.

2. The foam insert for a hat of claim 1 wherein first elongated radial extension has an orientation indicator.

3. The foam insert for a hat of claim 1 wherein at least one elongated radial extension has a plurality of trim notch indicators.

4. The foam insert for a hat of claim 1 further comprising EVA foam that has a density of greater than 3 pounds per cubic foot, a thickness greater than 0.14 inches and a tensile strength greater than 80 psi.

5. The foam insert for a hat of claim 1 wherein the first elongated radial extension has a length greater than the length of the second elongated radial extension and a length greater than the length of the third elongated radial extension.

6. A form insert for a hat, comprising: a plurality of elongated radial extensions that extend from a central crown portion and that have a thickness; a first of one of the plurality of elongated radial extensions defining two slots, one slot on a left perimeter and one slot on a right perimeter; a second of one of the plurality of elongated radial extensions having a tab, the tab configured to mate with either of the slots located on the first of one of the plurality of elongated radial extensions; and, wherein when the tab of the second of one of the plurality of elongated radial extensions is mated with the slot of the first of the plurality of elongated radial extensions, the foam insert for a hat forms a conical shape.

7. The foam insert for a hat of claim 6 wherein the thickness of the plurality of elongated radial extensions is less than a thickness of the crown portion.

8. The foam insert for a hat of claim 6 wherein each of the plurality of elongated radial extensions has a length, and one of the plurality of elongated radial extensions has a length less than any of the other of the plurality of elongated radial extensions.

9. A foam insert for a hat, comprising: a central crown portion; a front elongated radial extension that extends radially from the central crown portion; a rear elongated radial extension that extends radially from the central crown portion; three left side elongated radial extensions that each extend from the central crown portion; three right side elongated radial extensions that each extend from the central crown portion; at least two slots configured to receive tabs and defined in at least one of the elongated radial extensions; at least two tabs configured to mate with the at least two slots, the at least two tabs located on at least one of the elongated radial extensions; and, wherein the front elongated radial extension has a length and the length is longer than a length of any other elongated radial extension.

10. The foam insert for a hat of claim 9 wherein the front elongated radial extension has an orientation indicator.

11. The foam insert for a hat of claim 9 wherein at least three of the elongated radial extension has a plurality of trim notch indicators.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] FIG. 1 is a from perspective view of the assembled Insert for a Hat, showing the tab and slot features engaged, venting apertures and the general conical shape.

[0008] FIG. 2 is a rear perspective view of the assembled Insert for a Hat further showing the asymmetrical rear radial extension and incorporated arch feature.

[0009] FIG. 3 is a top plan view of an Insert for a Hat in its unassembled state.

[0010] FIG. 4 is a depiction of the fully assembled Insert for a Hat inserted in to a cap.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] In a preferred embodiment the insert disclosed herein is made of Ethylene-vinyl acetate (EVA) with a density of about 4 pounds per cubic foot, a thickness of about 0.16″ and a tensile strength of about 90 psi. The characteristics of the preferred EVA material may be varied depending on the application environment of the insert. For example, crown portion 12 may be made thicker than one or more of the plurality of radially arranged arms to provide more protection in that area.

[0012] Referring to FIGS. 1-4 bump cap insert 10 as disclosed herein is depicted. Bump cap insert 10 comprises a plurality of radially arranged extensions 14 that radiate from a common center 27. Each extension has a plurality of venting apertures 36 to provide ventilation between the wearer's head and the hat into which bump cap insert 10 is placed. When radially arranged extensions 14 come together during the assembly of bump cap 10 for insertion additional ventilation apertures 38 are created.

[0013] In a preferred embodiment, at least two sets of interlocking tabs and slots are employed. As can be seen in FIG. 3, radial extension 16 is configured with tab 22 and radial extension 20 is configured with tab 28. Radial extension 18 defines slot 24 located on its left perimeter and radial extension 18 defines slot 26 on its right perimeter. As can be seen in FIG. 1 when the bump cap insert is assembled tab 22 engages slot 24 and tab 28 engages slot 26. When the tabs and slots are engaged bump cap insert 10 forms a generally conical shape that conforms generally to the shape of a human head. It is contemplated that more than two pairs of tab and slot connectors can be used in the event a more stable structure is needed for certain hat shapes, for example, or certain applications that requires more structural stability is required.

[0014] The radially arranged extensions 14 include trim marks 32 that guide trimming of insert 10 if needed for a proper fit into a hat. Certain hat configurations, for example, maybe too short to allow insert 10 to be fully inserted into the hat without insert 10 being visible beneath the edges of the hat. The preferable multiple trim marks 32 located on each radial extension 14 also allow for more uniform trimming of adjacent radial extensions 14. The user may then trim insert 10 to fit the particular hat such that insert 10 is no longer visible. When used with ball style caps, such as cap 40 shown in FIG. 4, it is useful to be able to tuck the lower perimeter 39 of insert 10 into the internal cuff 42 of cap 40 to promote a stable fit. Trim marks 32 are useful to trim insert 10 to insure insert 10 fits into cap 40 and under internal cuff without any bunching of insert 10 to insure a comfortable and stable fit. The length of radially arranged extensions 14 is preferably asymmetrical with a longer radially arranged extension 18 located in the area of the insert facing forward and a shorter radially extension 13 facing rearward. Rearward facing radial extension 13 defines arch 15 to better accommodate different hat styles and hair styles. Referring to FIG. 4, radial extension 13 is preferably shorter, and defines arch 15, so as not to obstruct opening 44 on cap 40. This allows for different hair styles that fit through opening 44 to do so, unobstructed.

[0015] Radial extension 18 is marked with indicator 34 to allow a user to orientate radial extension 18 to the front of the hat, as seen in FIG. 5.

[0016] While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiments, it will be apparent to those of ordinary skill in the art that the invention is not to be limited to the disclosed embodiments. It will be readily apparent to those of ordinary skill in the art that many modifications and equivalent arrangements can be made thereof without departing from the spirit and scope of the present disclosure, such scope to be accorded the broadest interpretation of the appended claims so as to encompass all equivalent structures and products. Moreover, features or aspects of various example embodiments may be mixed and matched (even if such combination is not explicitly described herein) without departing from the scope of the invention.

[0017] For purposes of interpreting the claims for the present invention, it is expressly intended that the provisions of Section 112, sixth paragraph of 35 U.S.C. are not to be invoked unless the specific terms “means for” or “step for” are recited in a claim.