Abstract: The brim shaper device, a headwear accessory has binding tabs at each end, compression fitting the side edges of a cap bill and imparting a desired flat shape to the cap bill. Indicia may be placed on a top surface of the brim shaper device which covers the cap bill, The unitary shaped body of the invention is comprised of a lightweight, compact, cost-effective rigid material which also provides for enhanced portability of headwear while not in use.

Abstract: A cap shaper has contact-members adapted for supporting and shaping a cap from its inside; The cap shaper is elastically deformable under external forces, and maintains a generally larger contact-members' collective-outline dimension than that of the cap inside when free from external forces; When placed inside the cap the cap shaper deforms under the confines of the smaller cap inside due to the contact forces exerted to the contact-members from the contacted cap regions, displacing the contact-members, resulting cap shaper internal elastic tension and tendency to expand and substantially self-adapt for the contact-members to contact and fit in with the cap regions of contact, accommodating minor cap size and shape variations, counter balancing the contact forces and maintaining the tensioned contact to shape the cap.

Abstract: A method for printing on a lower surface of a peak of a baseball cap comprising: a) printing an image on the lower surface of the peak when the peak is at an elevated printing temperature and when the peak is in a generally planar configuration; b) allowing the peak to cool to a temperature below an elevated formation temperature; and, c) heating the peak to the elevated formation temperature and applying a non-planar shape to the peak, wherein the peak comprises a deformable insert that is solid at the elevated printing temperature and deformable at the elevated formation temperature.

Abstract: A cap shaper has contact-members adapted for supporting and shaping a cap from its inside; The cap shaper is elastically deformable under external forces, and maintains a generally larger contact-members' collective-outline dimension than that of the cap inside when free from external forces; When placed inside the cap the cap shaper deforms under the confines of the smaller cap inside due to the contact forces exerted to the contact-members from the contacted cap regions, displacing the contact-members, resulting cap shaper internal elastic tension and tendency to expand and substantially self-adapt for the contact-members to contact and fit in with the cap regions of contact, accommodating minor cap size and shape variations, counter balancing the contact forces and maintaining the tensioned contact to shape the cap.

Abstract: A hat pallet for use in a printer which prints an image onto a hat of the type having a cap and a brim attached thereto includes a bottom plate and a top plate mountable in a closed position over the bottom plate. The bottom plate includes a printing plate and a brim support fixedly mounted thereon. The top plate has an opening exposing at least a portion of the printing plate when the top plate is in the closed position. The brim support is positioned relative to the printing plate such that when the hat is mounted in the pallet with the top plate in the closed position, a portion of the cap on which the image is to be printed is supported on the printing plate and exposed through the opening of the top plate and the underside of the brim of the hat is supported by the brim support.

Abstract: A ball cap shaper for restoring and maintaining an original pre-washed shape of a ball cap. The ball cap shaper generally includes a support apparatus having a lower surface and an upper surface, the lower surface being substantially planar, the upper surface having a curved-hemispherical shape. The support apparatus is comprised of a compressible and resilient material. An absorbent member having a lower surface and an upper surface covers at least a portion of the support apparatus, wherein the lower surface of the absorbent member is in contact with the upper surface of the support apparatus to substantially cover an entire the upper surface of the support apparatus. The upper surface of the absorbent member faces outwardly from the support apparatus and adapted to receive an inside surface of a crown of a cap for retaining a curved-hemispherical shape of the cap and absorbing moisture from the crown.

Abstract: A cap drying and shaping apparatus includes a substantially planar base, an inflatable bladder disposed proximal one end of the planar base, and a ribbed cage member. The ribbed cage member includes a domed portion having a predetermined radius to the apex and a predetermined diameter parallel to the planar base, and a planar portion at least as long and wide as a bill on a typical ball cap. Attachment means are disposed on top of the planar base for removably clamping the ribbed cage member to the planar base.

Abstract: The technology described herein provides a device and associated methods for storing, displaying, and shaping hats, caps, or the like. This device includes multiple rings of the same diameter and multiple rings of varied diameters to provide for the storing and displaying of a multiplicity of hats while simultaneously maintaining the curvature of the brim portion of the hat. This device provides for the training of the brim of a hat to a particular degree of curvature as desired by the wearer and as selected from the multiple rings of varied diameters of the device. Other comparable uses are also contemplated herein, as will be apparent to those of ordinary skill in the art.

Abstract: A hat pallet for use in a printer which prints an image onto a hat of the type having a cap and a brim attached thereto includes a bottom plate and a top plate mountable in a closed position over the bottom plate. The bottom plate includes a printing plate and a brim support fixedly mounted thereon. The top plate has an opening exposing at least a portion of the printing plate when the top plate is in the closed position. The brim support is positioned relative to the printing plate such that when the hat is mounted in the pallet with the top plate in the closed position, a portion of the cap on which the image is to be printed is supported on the printing plate and exposed through the opening of the top plate and the underside of the brim of the hat is supported by the brim support.

Abstract: A shape supporting and form maintaining device, known as a “HatNoodle”, for a cap. The cap includes two components, an essentially hemispherical crown component and an attached visor component. The aforementioned “HatNoodle” device is constructed from a resilient material and includes a bottom surface and an essentially convex top surface. The bottom surface may contain a plurality of insertion holes that extend into, but not completely through, the material of the device and are used when installing the device into a cap. The top surface of the device contains a plurality of compliance slots wherein each compliance slot begins at the center of the top surface of the device and proceeds outward in a radial direction. The compliance slots facilitate installing a cap onto the device. These compliance slots also allow the device to better conform to the shape of the inside surface of the crown of the cap hat it resides within.

Abstract: An ornamental visor-bending device with a strand that is bent, formed and cut, comprises a laterally arched member running substantially from one side of a baseball cap type visor to the other side. The device further includes end members on each end of the strand which releasably attach and constrain the edges of the opposing sides of the visor and force the central portion of the visor to conform to an arch or other useful shape. The visor-bending device may be worn with the visor on the head of the user to maintain the bend of the visor. The laterally arched strand may itself be made ornamental with or without additional ornamentation attached. The end members are ornamental and have additional ornamentation attached.

Abstract: A combination hat rack structure includes a domed housing, a support seat, and a frame. The combination hat rack structure may provide a plane display effect, may be suspended on the wall, and may be disposed in an inclined manner, thereby enhancing the versatility of the combination hat rack structure.

Abstract: This invention satisfies a long felt need to protect a typical baseball type cap from the crushing forces often associated with shipping and packaging. This invention incorporates the not previously used idea of a half-crown or full-crown insert to support the cap from underneath against crushing forces occurring during shipping which tend to make an unsupported hat have a sloppy, wrinkled and undesirable appearance. The insert is retained inside the baseball type cap by tucking it into or around the sweatband. The industry has typically used outer rigid packaging covers to protect the cap during shipping and packaging. While these covers protect the cap from crushing forces, they do not support the crown portion from underneath. An underneath supporting insert will force the cap to retain its shape for long periods of time and can be used by the retail purchaser to retain the cap's shape when not in use.

Abstract: A device and method of shaping the visors of caps is disclosed. In the device, a visor shaping unit has a movable upper mold and a fixed lower mold. The upper mold, with a coil heater, is outwardly curved into a predetermined curvature at its lower surface and is operated by a hydraulic cylinder. The lower mold is inwardly curved into the same curvature as that of the upper mold at the top surface. The cooling unit has first to third chambers with a plurality of perforated sections being formed on the top wall of each of the chambers. Upper and lower panels are exteriorly attached to the top wall of each chamber at a position covering each perforated section. The two panels define a curved gap between them, thus holding a heated visor in the gap during a cooling process. The visors are heated at about 90.degree. C. to 150 .degree. C. for about 5-20 seconds in the visor shaping unit prior to being cooled in the cooling unit for about 10-30 seconds using cool air having a temperature of about 5-20 .degree. C.

Abstract: A device and method of shaping the visors of caps is disclosed. In the device, a visor shaping unit has a movable upper mold and a fixed lower mold. The upper mold, with a coil heater, is outwardly curved into a predetermined curvature at its lower surface and is operated by a hydraulic cylinder. The lower mold is inwardly curved into the same curvature as that of the upper mold at the top surface. The cooling unit has first to third chambers with a plurality of perforated sections being formed on the top wall of each of the chambers. Upper and lower panels are exteriorly attached to the top wall of each chamber at a position covering each perforated section. The two panels define a curved gap between them, thus holding a heated visor in the gap during a cooling process. The visors are heated at about 90.degree. C. to 150.degree. C. for about 5-20 seconds in the visor shaping unit prior to being cooled in the cooling unit for about 10-30 seconds using cool air having a temperature of about 5-20.degree. C.

Abstract: A combination automatic molding machine and associated cooling rack for pressed items, such as hats, using advanced features which produce a pressed items, such as a completed hat form from an unshaped configuration of a moldable material, such as felt, wool or straw. The combination can also be used to produce other flexible, inelastic fabric structures, such as molded insulation members within a wall or vehicle body. When a hat is first taken from the hat molding machine at a first large size, it is then placed upon the cooling rack, where the size is further varied by placing corresponding male crown inserts extending up from a flange placed upon the cooling rack. Preferably the male inserts are made of ABS Plastic. In effect, the molding rack is used to vary sizes for each hat upon the cooling rack. While the hat is in a warm, malleable state of a large size, the hat thus formed is squeezed through a fenestration hole of a smaller size reducer.

Abstract: A hat molding machine using advanced features will produce a completed hat form from an unshaped felt or wool configuration. The machine employs male and female hat molds. The female hat mold has embedded electric heating elements which are temperature controlled. Low pressure steam is piped into the female mold. Using three pneumatic cylinders and an automatic programmable air controller with timer for proper sequencing, a completed hat form shape including shape portion and flange brim portion results.

Abstract: A hat molding machine using advanced features will produce a completed hat form from an unshaped felt or wool configuration. The machine employs male and female hat molds. The female hat mold has embedded electric heating elements which are temperature controlled. Low pressure steam is piped into the female mold. Using three pneumatic cylinders and an automatic programmable air controller with timer for proper sequencing, a completed hat form shape including shape portion and flange brim portion results.

Abstract: A hat brim press including a base plate with a planar top surface portion for supporting the bottom of a hat brim; a cover plate having an annular, planar bottom surface for engaging the top of the hat brim; the cover plate defining a central opening encircled by the bottom surface and adapted to accommodate a crown attached to the hat brim; and fasteners connecting the base plate and the cover plate and manually adjustable to produce between the top surface portion and the bottom surface forces directed orthogonally thereto, the forces pressing the hat brim between the top surface portion and the bottom surface so as to retain the hat brim in a planar form.