Stretchable sweatband for a cap

Abstract

A sweatband used for headwear that is woven of 100% combustible synthetic yarn without any polyurethane. The sweatband provides excellent sweat absorbing capability and exhibits good elasticity through the structure of the textile without imposing undue pressure on the wearer so that the sweatband may be worn comfortably for a long period of time. The yarn used to produce the sweatband is passed through a bulky process, being shrunk through a low temperature short-term combustion method and dry heat treatment process after weaving. The sweatband preferably has a unitary, single ply construction that is planar and does not twist in the absence of elongating force.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention is related to the field of headwear and, more particularly, to an improved stretchable sweatband woven as one unit body and having a highly efficient sweat-absorbing capability.

2. Description of the Related Art

Caps of the baseball-style type generally include a crown main body, a visor portion that is secured to the forward edge of the crown and extends outwardly therefrom, a headband or sweatband attached to the lower part of the inside of the crown, and a size controller attached to an underside of the rear of the cap. Alternatively, cap sweatbands have been constructed that include an elastic band made of fabric which includes spandex yarn, giving the sweatband size flexibility while eliminating the size controller.

It has been found, however, that caps relying on spandex sweatbands for sizing exert pressure against the wearer's head which can become uncomfortable after the cap is worn for an extended period of time.

Accordingly, a need exists for an improved sweatband that does not exert undue pressure on the wearer's head and therefore may be worn comfortably for extended time periods.

SUMMARY OF THE INVENTION

In view of the foregoing, one object of the present invention is to provide headwear with a sweatband that does not exert undue pressure on the head when worn.

Another object of the present invention is to provide a cap having excellent sweat-absorbing capability.

A further object of the present invention is to produce a sweatband by weaving combustible synthetic yarn of 100% nylon with no polyurethane.

Yet another object of the present invention is to provide a sweatband that affords elasticity through the structure of the textile, the yarn from which the sweatband is made being subjected to a bulking and shrinking process which leaves the sweatband flat and suitable for use with headwear.

A still further object of the present invention is to provide a sweatband of sufficient elasticity to provide variable sizing to a cap without the need for a separate size controller.

Another object of the present invention is to provide a sweatband that is unitary in construction without any additional stitch work for connection to headwear.

In accordance with these and other objects, the present invention is directed to a sweatband mainly used for headwear and woven by 100% nylon combustible synthetic yarn to produce a unitary body without additional stitch work. After weaving the nylon yarn, the sweatband is passed through a bulky process and then processed to be shrunk through a low temperature short-term combustion method, followed by drying through a heat treatment process to produce a file-shaped, planar length of elastic material that does not twist in the middle when relaxed. Having no polyurethane, the sweatband demonstrates elasticity as a whole due to the structure of the textile. The circumferential stretch direction of the sweatband also provides excellent sweat absorption capability and a wide range of automatic size adjustment may be obtained without imposing undue elastic pressure on the wearer.

These together with other objects and advantages which will become subsequently apparent reside in the details of construction and operation as more fully hereinafter described and claimed, reference being had to the accompanying drawings forming a part hereof, wherein like numerals refer to like parts throughout.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a bottom perspective view of a baseball-style cap with a sweatband according to the present invention;

FIG. 2 is a perspective view of the stretchable sweatband according to the present invention;

FIG. 3-1 is a side view of the sweatband showing the yarn shape before the stretchable sweatband is expanded; and

FIG. 3-2 is a side view of the sweatband showing the yarn shape after the stretchable sweatband is expanded.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

In describing preferred embodiments of the invention illustrated in the drawings, it is to be understood that these embodiments are given by way of illustration only. It is not intended that the invention be limited in its scope to the details of construction and arrangement of components set forth in the following description or illustrated in the drawings. Also, in describing the preferred embodiments, specific terminology will be resorted to for the sake of clarity. It is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar purpose.

The present invention is directed to a sweatband suitable for use with headwear of various types, but is described herein in connection with a baseball-style cap as shown in FIG. 1. It is understood that the inventive sweatband may also be used with other types of headwear or even alone.

According to the embodiment illustrated in FIG. 1, the present invention is directed to a baseball-style cap including a crown main body, generally designated by the reference numeral 1, a visor portion, generally designated by the reference numeral 2, and a sweatband, generally designated by the reference numeral 3. The crown part 1 is generally made of more than one piece of fabric, having several panels. The visor portion 2 is secured to the forward edge of the crown main body 1, and the sweatband 3 is secured to the lower peripheral edge of the interior of the crown 1.

As shown in FIG. 2, the stretchable sweatband 3 is woven with combustible synthetic yarn to preferably have a unitary construction of a single ply 4. The sweatband has a file-shaped, planar construction that does not twist in the middle when the sweatband is relaxed, i.e., when no elongating force is applied thereto.

According to the preferred embodiment, the yarn is 100% nylon and, when woven into the sweatband 3 as shown, virtually eliminates any feeling of pressure on the wearer's head, even when worn for extended periods of time. The sweatband 3 also demonstrates excellent sweat absorbing capability. The sweatband may alternatively be constructed to be two-ply if desired. Whether or single ply or two-ply, the woven shape according to the present invention renders the sweatband stretchable as a result of the structure of the textile. The sweatband does not include or require an additional stitching portion for connection of the sweatband to headwear.

The present invention further includes a method of processing the nylon yarn used to produce the sweatband. After the weaving thereof, the nylon yarn is passed through a bulky process, shrunk through a low temperature, short-term combustion method and then processed according to a dry heat treatment process. FIG. 3-1 illustrates the shape of the yarn before the stretchable sweatband is expanded, i.e., subjected to an elongating force as occurs when the sweatband is placed on the wearer's head, and FIG. 3-2 illustrates the shape of the yarn following elongation or expansion; the direction of the expansion is indicated by the arrows. When the sweatband is attached to headwear, such as a cap, and is placed on the wearer's head, the cap shows the effect of being stretched by the file-shaped sweatband and the structure of the textile with the nylon yarn. The resulting sweatband made with this method, providing stretchability through the structure of the textile, may be extended to up to 60% after 10 seconds under 1.8 kg of weight, and exhibits a 0.0% to 0.2% residual rate within 30 seconds after removal of the weight.

The foregoing descriptions and drawings should be considered as illustrative only of the principles of the invention. The invention may be configured in a variety of shapes and sizes and is not limited by the dimensions of the preferred embodiment. Numerous applications of the present invention will readily occur to those skilled in the art. For example, the headband may be incorporated into hats, caps and visors of other styles, or may be used alone. Therefore, it is not desired to limit the invention to the specific examples disclosed or the exact construction and operation shown and described. Rather, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.

Claims

1. A stretchable sweatband for headwear, said sweatband woven with 100% nylon combustible synthetic yarn that contains no polyurethane.

2. The sweatband as set forth in claim 1, wherein said sweatband is formed as a single unit body without additional stitch work for connection to headwear.

3. The sweatband as set forth in claim 2, wherein said sweatband has a file-shaped planar construction that does not twist in a middle portion thereof.

4. The sweatband as set forth in claim 1, wherein the sweatband is single ply.

5. The sweatband as set forth in claim 1, wherein the sweatband is two-ply.

6. Headwear comprising:

a crown main body;

a visor portion secured to a peripheral edge of said crown main body and extending outwardly therefrom; and

a sweatband woven with 100% nylon combustible synthetic yarn that contains no polyurethane.

7. The headwear as set forth in claim 6, wherein said sweatband is formed as a single unit body without additional stitch work for connection to said crown main body.

8. The headwear as set forth in claim 7, wherein said sweatband has a file-shaped planar construction that does not twist in a middle portion thereof.

9. The headwear as set forth in claim 6, wherein the sweatband is single ply.

10. The headwear as set forth in claim 6, wherein the sweatband is two-ply.

11. A method for forming a sweatband:

weaving 100% nylon combustible synthetic yarn that contains no polyurethane into a unitary body;

processing said yarn by shrinking through a low temperature, short-term combustion method; and

subjecting said yarn to a dry heat treatment process to produce a file-shaped planar sweatband that does not twist in a middle portion thereof.