Braided Article of Headgear and Method of Making

Abstract

A braided article of headgear and a hat form are disclosed. In one embodiment, the hat form has a double crown portion and a double bill portion. The braided article comprises a braided construction with at least one strand that extends continuously from a right portion of the crown to a left portion of the crown. The braided article may include a single layer or a double layer construction comprising an inner braid layer and an outer braid layer.

Description

BACKGROUND

The present embodiments relate generally to articles, and in particular to articles of headgear that incorporate braided components.

Articles of headgear may include hats, helmets and other kinds of headgear. Hats may generally a crown and a brim. The crown generally fits on a user's head and the brim extends out away from the crown. In some cases, the brim extends forward as a visor. Hats can also include decorations, such as embroidered designs with team logos or other indicia.

SUMMARY

In one embodiment, an article of headgear having a crown is characterized by having a coronal plane, a transverse plane, and a sagittal plane. The crown has an interior void sized and configured to receive a wearer's head; the crown includes a front portion disposed generally forward of the coronal plane and a rear portion disposed opposite the front portion. The rear portion disposed generally rearward of the coronal plane. The crown includes a left side portion disposed on one side of the sagittal plane, and a right side portion disposed opposite the left side portion, on the other side of the sagittal plane. The crown includes a braided construction with at least one strand. The strand extends continuously from the left side portion to the right side portion.

In another embodiment, a hat form used to create an article of headgear includes a first side and a second side opposite the first side, where the first side is integrally formed with the second side. The first side includes a first crown portion. The second side includes a second crown portion. The first crown portion generally aligns with the second crown portion, thereby forming a double-hat form. The hat form is configured to be fed into a braiding machine and receive an overbraided matrix of strands on its outer surface.

In another embodiment, an article of headgear has a crown, the crown having coronal plane, a transverse plane and a sagittal plane. The crown includes an interior void sized and configured to receive a wearer's head. The crown includes a front portion disposed generally forward of the coronal plane and a rear portion disposed opposite the front portion, the rear portion disposed generally rearward of the coronal plane. The crown includes a left side portion disposed on one side of the sagittal plane, and a right side portion disposed opposite the left side portion, on the other side of the sagittal plane. The crown includes an inner braid layer and an outer braid layer.

Other systems, methods, features, and advantages of the embodiments will be, or will become, apparent to one of ordinary skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description and this summary, be within the scope of the embodiments, and be protected by the following claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the embodiments. Moreover, in the figures, like reference numerals designate corresponding parts throughout the different views.

FIG. 1 is a schematic view of an embodiment of a hat form and a braiding machine;

FIG. 2 is a schematic view of an embodiment of a hat form and several supplementary structures;

FIG. 3 is a schematic view of another embodiment of a hat form with several supplementary structures;

FIG. 4 is a schematic view of an embodiment of a step in a method of making an article of headgear;

FIG. 5 is a schematic view of an embodiment of another step in a method of making an article of headgear;

FIG. 6 is a schematic view of an embodiment of another step in a method of making an article of headgear;

FIG. 7 is a schematic view of an embodiment of another step in a method of making an article of headgear;

FIG. 8 is a schematic view of an embodiment of a process for forming an article of headgear with different density regions;

FIG. 9 is a schematic view of another embodiment of a process for applying braided strands to a hat form;

FIG. 10 is a schematic view of an embodiment of a step in a method of making a double-layered article of headgear;

FIG. 11 is a schematic view of an embodiment of another step in a method of making a double-layered article of headgear;

FIG. 12 is a schematic view of an embodiment of another step in a method of making a double-layered article of headgear;

FIG. 13 is a schematic view of an embodiment of a hat form and a braiding machine, in which the hat form includes a double under bill portion;

FIG. 14 is a top schematic view of an embodiment of a braided construction in the form of a hat with an over peak bill portion and an under peak bill portion;

FIG. 15 is a schematic view of an embodiment of a step of forming an article of headgear;

FIG. 16 is a schematic view of an embodiment of another step of forming an article of headgear;

FIG. 17 is a schematic view of an embodiment of an article of headgear comprising of a braided construction; and

FIG. 18 is a schematic view of the article of headgear of FIG. 17, in which multiple continuous strands are explicitly highlighted.

DETAILED DESCRIPTION

In the following detailed description, reference is made to the accompanying figures that form a part hereof wherein like numerals designate like parts throughout, and in which is shown, by way of illustration, embodiments that may be practiced. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present disclosure. Therefore, the following detailed description is not to be taken in a limiting sense, and the scope of embodiments is defined by the appended claims and their equivalents.

Aspects of the disclosure are disclosed in the accompanying description. Alternate embodiments of the present disclosure and their equivalents may be devised without parting from the spirit or scope of the present disclosure. It should be noted that any discussion herein regarding “one embodiment,” “an embodiment,” “an exemplary embodiment,” and the like indicates that the embodiment described may include a particular feature, structure, or characteristic that may not necessarily be included in every embodiment. In addition, references to the foregoing do not necessarily comprise a reference to the same embodiment. Finally, irrespective of whether it is explicitly described, one of ordinary skill in the art would readily appreciate that each of the particular features, structure, or characteristics of the given embodiments may be utilized in connection or combination with those of any other embodiment discussed herein.

Various operations may be described as multiple discrete actions or operations in turn, in a manner that is most helpful in understanding the claimed subject matter. However, the order of description should not be construed as to imply that these operations are necessarily order dependent. Operations described may be performed in a different order than the described embodiment. Various additional operations may be performed and/or described operations may be omitted in additional embodiments.

For the purposes of the present disclosure, the phrase “A and/or B” means (A), (B), or (A and B). For the purposes of the present disclosure, the phrase “A, B, and/or C” means (A), (B), (C), (A and B), (A and C), (B and C), or (A, B, and C).

The terms “comprising,” “including,” “having,” and the like, as used with respect to embodiments of the present disclosure, are synonymous.

As used herein, the term “article” refers broadly to articles of footwear, articles of apparel (e.g., clothing), as well as accessories and/or equipment. Articles of footwear include, but are not limited to, hiking boots, soccer shoes, football shoes, sneakers, running shoes, cross-training shoes, rugby shoes, basketball shoes, baseball shoes as well as other kinds of shoes. Moreover, in some embodiments, components may be configured for various kinds of non-sports-related footwear, including, but not limited to, slippers, sandals, high-heeled footwear, loafers as well as any other kinds of footwear. Articles of apparel include, but are not limited to, socks, pants, shorts, shirts, sweaters, undergarments, hats, gloves, as well as other kinds of garments. Accessories include scarves, bags, purses, backpacks, as well as other accessories. Equipment may include various kinds of sporting equipment including, but not limited to, bats, balls, various sporting gloves (e.g., baseball mitts, football gloves, ski gloves, etc.), golf clubs, as well as other kinds of sporting equipment. In some embodiments discussed below, an article is an article of headgear configured to be worn on a wearer's head.

To assist and clarify the subsequent description of various embodiments, various terms are defined herein. Unless otherwise indicated, the following definitions apply throughout this specification (including the claims). For consistency and convenience, directional adjectives are employed throughout this detailed description corresponding to the illustrated embodiments.

The term sagittal plane or median plane (longitudinal, anteroposterior), as used throughout the detailed description and in the claims refers to a plane parallel to the sagittal suture. It divides the body into left and right. The term coronal plane or frontal plane (vertical), as used throughout this detailed description and in the claims refers to a plane dividing the body into dorsal and ventral (back and front, or posterior and anterior) portions. Furthermore, the term transverse plane (also called the horizontal plane, axial plane, or transaxial plane) as used throughout this detailed description and in the claims refers to is a plane that divides the body into superior and inferior parts. It is perpendicular to the coronal plane and sagittal plane.

In some embodiments, hats and forms for hats are disclosed. A hat generally has a crown (or crown portion) and a brim (or brim portion). The crown generally fits on a user's head and the brim extends out away from the crown. In some cases, the brim extends forward as a visor. Correspondingly, a hat form may also have a crown portion and a brim portion, which are the portions of the form used to create the crown and brim of a manufactured hat.

In some embodiments, hats may include additional components, such as a sweat band. A sweat band may be disposed on an inner surface of the crown, or alternatively, between two or more layers of a multilayered crown. In other cases, a hat may not include a sweat band. In some embodiments, hats could include a bill-reinforcing element. Such a reinforcing element may be disposed on an inner surface of the bill, on an outer surface of the bill or between two or more layers.

As used herein, a hat may comprise one or more “sides” or opposing portions. For example, the crown may comprise a front portion disposed generally forward of the coronal plane and a rear portion disposed opposite the front portion. The rear portion may be generally disposed rearward of the coronal plane. In some cases, the front portion faces toward the brim. The crown may also comprise a left side portion disposed on one side of the sagittal plane, and a right side portion disposed opposite the left side portion, on the other side of the sagittal plane.

FIG. 1 depicts an embodiment of a braiding machine and a hat form. Braiding machine 102 includes a plurality of spools that include strands or threads. The spools pass by one another along a track such that plurality of strands 104 intertwine and twist with one another. This twisting and intermeshing of plurality of strands 104 forms a braided structure (i.e., a structure having a braided construction). Although depicted as a radial braiding machine, it should be recognized that an axial braiding machine or other type of braiding machine may be utilized. Further, the braiding machine may also be configured to perform jacquard and non-jacquard motions. An example of a braiding machine is described in Richardson, U.S. Pat. No. 5,257,571, granted Nov. 2, 1993, entitled “Maypole Braider Having a Three Under and Three Over Braiding Path,” the entirety of which is hereby incorporated by reference. Additionally, another example of a braiding machine is described in Dow et al., U.S. Pat. No. 7,908,956, granted Mar. 22, 2011, entitled “Machine for Alternating Tubular and Flat Braid Sections,” the entirety of which is hereby incorporated by reference. An example that includes a former that is passed through a braiding machine is described in Dodge et al., U.S. Pat. No. 376,372, granted Jan. 10, 1888, entitled “Manufacture of Woolen Boots,” the entirety of which is hereby incorporated by reference.

Braiding machine 102 may be utilized to overbraid an object. “Overbraid” as used herein shall refer to a method of braiding that forms the shape of a three-dimensional structure. An object or structure that is overbraided includes a braid structure that extends around an outer surface of the structure. An object need not be completely covered by a braid structure to be considered overbraided. Rather, an object that is overbraided includes a seamless braided structure that extends around a portion of the object. As an object is overbraided, strands are deposited along an outer surface of the object.

An object is overbraided as the object passes through the braiding point. The braiding point is defined as the point or area where plurality of strands 104 consolidate to form a braided structure. As plurality of strands 104 approach the braiding point, the distance between each of the strands is diminished. As the distance between the strands reduces, the strands from the different spools intermesh or braid with one another in a tighter fashion. The braiding point refers to an area where the desired tightness or strand density has been achieved on the braiding machine.

Plurality of strands 104 may be formed of different materials. The properties that a particular strand will impart to an area of a braided structure depend on the materials that form the various filaments and fibers within the strands. For example, the filaments may be formed of cotton. Cotton may provide a soft hand, natural aesthetics as well as biodegradability. Other embodiments may include elastane or stretch polyester. In still further embodiments, nylon may be incorporated. Nylon is a durable, abrasion-resistant material with relatively high strength that may be incorporated into areas of an article that are more likely to be exposed to high stress or scraping than other areas. Polyester may be incorporated due to its hydrophobic nature. For example, a waterproof or water-resistant article may incorporate polyester. Additionally, various materials may be utilized for sweat removal or wicking. The materials chosen may also include properties that permit the material to melt or bond to various components. For example, the materials may include thermoplastic or thermoset materials as well as other heat-activated materials. Additionally, other materials may be utilized for various material properties. In addition to material, other aspects of the strand may be altered to affect the properties of the braided structure. For example, a strand may include monofilament or multifilament thread. The strand may also include separate filaments that are formed of different materials, such as bicomponent strands.

The following figures depict methods and apparatuses used to form an article of headgear (e.g., a hat) using a hat form. In some embodiments, an article of headgear may be formed in conjunction with a braiding machine. As described in further detail below, hat form 100 may be passed through braiding machine 102. To assist in clearly depicting the method used to form an article incorporating a braided component, braiding machine 102 is depicted without spools or a support structure in the figures. Although depicted without a support structure or spools, it should be recognized that braiding machine 102 as well as other braiding machines depicted in this detailed description may include spools or other known provisions used in overbraiding or other kinds of braiding processes.

Referring to FIG. 1, hat form 100, also referred to simply as “form” 100, may be further comprised of first side 120 and second side 130. Moreover, each side has the geometry of a hat, with the two sides being approximately symmetric about central plane 140 of hat form 100. In particular, first side 120 has first crown portion 122. In some embodiments, first side 120 also includes first bill portion 124 connected to first crown portion 122. Also, second side 130 includes second crown portion 132. In some embodiments, second side 130 also includes second bill portion 134 connected to second crown portion 132. In some embodiments, first crown portion 122 and second crown portion 132 may be approximately aligned. Alternatively, in other embodiments, hat form 100 may only include opposing crown portions without any bill portions. Such a form may be useful in manufacturing caps without visors or brims.

Taken together, first crown portion 122 and second crown portion 132 form a “double crown portion” of hat form 100. In some embodiments, first bill portion 124 and second bill portion 134 may be approximately aligned. Taken together, first bill portion 124 and second bill portion 134 form a “double bill portion” of hat form 100. Moreover, the double crown portion and double bill portion provide a double hat form that can be used to make two articles of headgear simultaneously as an overbraid matrix of strands are applied to hat form 100.

In some embodiments, first side 120 and second side 130 may be integrally formed, as seen in the enlarged cross-sectional view of hat form 100 shown in FIG. 1. In some cases, first side 120 and second side 130 may be formed of a single monolithic material, such as wood, plastic, or metal. In other embodiments, first side 120 and second side 130 may be fixedly attached, for example, using fasteners or adhesives.

As seen in FIG. 1, the opposing crown portions and bill portions of hat form 100 may be separated by central gap 150 that extends around the perimeter of hat form 100 (and approximately within central plane 140). In some cases, this gap may facilitate the cutting or separation of a first braided hat and a second braided hat that may be formed by overbraiding onto hat form 100. Alternatively, in other embodiments, central gap 150 may be absent so that first crown portion 122 connects continuously with second crown portion 132 and so that first bill portion 124 connects continuously with second bill portion 134.

Although hat form 100 is shown with the double bill portion oriented toward braiding machine 102, it may be understood that hat form 100 could be fed in bill first (i.e., in the direction shown) or crown first (i.e., in an opposite direction to that shown in FIG. 1). In still other embodiments, hat form 100 could be oriented at any other angle as it's passed through braiding machine 102.

In FIG. 1, hat form 100 is shown without any additional provisions. However, in some embodiments, provisions can be included that help retain threads on hat form 100 as hat form 100 passes through braiding machine 102. In some embodiments, a light adhesive layer could be applied to some or all of the outer surface of hat form 100. In another embodiment, an additional layer with a higher coefficient of friction (relative to the threads) could be used. In some cases, a thin deformable outer layer could be used. In some cases, a thin rubber layer could be used. As an example, FIG. 9 depicts an embodiment where hat form 900 is covered with thin rubber layer 902. As hat form 900 is pushed through braiding machine 910, thin rubber layer 902 deforms slightly and retains threads 912. This may help limit the movement of threads along the surface of a hat form.

In some embodiments, one or more elements may be added to a hat form prior to (or during) overbraiding. In some embodiments, a band (e.g., sweat band) could be applied around each crown portion of a hat form. In some embodiments, a bill-reinforcing member could be applied against each bill portion.

FIG. 2 is a schematic view of hat form 100 in which band 202 and bill reinforcing member 204 are applied to first side 120. Specifically, band 202 is configured to be wrapped around first crown portion 122. Also, bill reinforcing member 204 is configured to be placed against first bill portion 124. In some cases, an adhesive could be used to temporarily hold band 202 and/or bill reinforcing member 204 in place on hat form 100.

As hat form 100 is placed through braiding machine 102 (see FIG. 1), both band 202 and bill reinforcing member 204 may also be overbraided. Moreover, in some cases band 202 and/or bill reinforcing member 204 could be retained on the final braided hat. In some cases, an adhesive could be applied to the outer sides of band 202 and/or bill reinforcing member 204 so that as threads are applied around hat form 100, band 202 and/or bill reinforcing member 204 remain attached when the final braided article of headgear is removed from hat form 100.

In another embodiment, depicted in FIG. 3, hat form 300 includes recesses to receive band 302 and bill reinforcing member 304. In particular, hat form 300 includes first band recess 310 for receiving band 302 and first bill recess 312 for receiving bill reinforcing member 304. Moreover, it may be appreciated that second side 330 of hat form 300 also includes second band recess 320 and a second bill recess (not visible in FIG. 3). Such recesses may allow bands, reinforcing members, and/or other elements to be retained on a hat form with little to no adhesive. Additionally, these provisions may help smooth out the outer surface of the final braided article, limiting bulges that might be formed in the regions associated with bands, bill reinforcing members, or other elements.

FIGS. 4-7 illustrate schematic views of a method of making articles of headgear (e.g., hats) using a hat form and a braiding machine, according to an embodiment. In FIGS. 4-5, as hat form 100 passes through the braiding point of braiding machine 102, strands from plurality of strands 104 are deposited along an outer surface of hat form 100. In this manner, hat form 100 may be overbraided by plurality of strands 104, forming braided layer 402. Moreover, using this overbraiding process, the strands that are laid down as part of braided layer 402 are continuous and span across multiple regions or portions of the final braided part. In some embodiments, strands extend continuously across both the double bill portion and the double crown portion of a hat form. As seen in FIGS. 4-5, any supplemental structures disposed on hat form 100 may be overbraided as well (e.g., band 202).

As seen in FIG. 5, with hat form 100 pushed completely through braiding machine 102, continuous tube 406 of the braided matrix continues from hat form 100 back to the braiding point of braiding machine 102. Thus, in some cases, the process may require cutting continuous tube 406 to separate hat form 100 and braided layer 402 from braiding machine 102. For purposes of illustration, front portion 404 of braided layer 402, disposed along the double bill portion of hat form 100 is shown as having a closed structure. However, in some cases, front portion 404 may be open like the rear portion is open adjacent continuous tube 406.

Once a hat form has been completely overbraided and separated from strands still attached to a braiding machine, a next step in making articles of headgear includes cutting and removing the resulting braided structure from the hat form. Therefore, in some embodiments, plurality of strands 104 (now part of braided layer 402) may be cut so that the braided matrix can be removed from hat form 100 for additional processing. As seen in FIG. 6, braided layer 402 may be cut along a path adjacent central gap 150. In some embodiments, shears or blade 602 may be used to cut plurality of strands 104. In other embodiments, lasers may be utilized. In still further embodiments, heat may be used to melt plurality of strands 104 to assist in the removal of braided layer 402 from hat form 100.

This step may result in the formation of two separate braided structures: first braided hat 610 and second braided hat 620 that have been formed on opposing sides of hat form 100. Thus, it may be seen that the use of a hat form with a double crown portion and a double bill portion provides two separate braided hats once the overbraided layer (or braid matrix) has been cut and separated from the hat form.

It may be appreciated that the steps illustrated in FIGS. 4-6 and described above may be used for any embodiments of a hat form, including embodiments with band and/or reinforcing member recesses (such as the embodiment depicted in FIG. 3). That is, different embodiments of a hat form may generally be overbraided over using a braiding machine and the resulting braid structure may be cut or otherwise separated into two distinct braided hats and removed from the hat form. Furthermore, as described in further detail below, some embodiments may comprise a braided structure with two or more braided layers (formed by passing a form through a braiding machine twice). In such embodiments, both layers can be separated simultaneously from a hat form in a similar manner to the method described here and shown in FIG. 6.

FIG. 7 illustrates a schematic view of a step of finishing one or more braided hats according to an embodiment. Referring to FIG. 7, first braided hat 610 and second braided hat 620 are shown. In this example, second braided hat 620 has been completely finished while first braided hat 610 is partially finished.

In some embodiments, the edges of first braided hat 610 and/or second braided hat 620 may comprise free thread ends 762 that may be subject to loosening or fraying if left exposed. In some embodiments, a trim or finishing edge may be applied to cover and/or fix free thread ends 702 in place. In the embodiment of FIG. 7, finishing edge 750 has been applied to lower peripheral edge 612 of first braided hat 610. Also, finishing edge 752 has been applied to lower peripheral edge 622 of second braided hat 620.

In different embodiments, edges can be finished in different ways. In some embodiments, edges can be finished by melting or otherwise fusing the free thread ends of a braided structure. In other embodiments, one or more pieces of a finishing material can be laid down on an edge. Exemplary materials that could be used include, but are not limited to, thermoplastic urethane (TPU), leather, synthetic leather as well as other kinds of materials. In some cases, finishing materials could be bonded to an edge using an adhesive. In other cases, heat and/or pressure could be applied to fuse a finishing material to an edge of a braided structure. In still other embodiments, the edges of a hat could be created by embroidering or knitting additional threads along the edge. Such embroidery or knit threads can help lock the free threads of a braided structure in place and also provide a finished look to the edges.

In some embodiments, the density of a braided structure could be varied by changing the speed at which a hat form is pushed through a braiding machine. Such provisions could allow for a front part of a hat to have a higher density braid than the rear part of the hat. This may be useful since it may be desirable to add additional embroidery or other stitching (e.g., adding embroidered logos) to the front of the hat. An exemplary process is depicted in the flow chart of FIG. 8. In first step 802, a first portion (e.g., front portion of the double crown portion) of a hat form is moved at a first speed through a braiding machine to form a portion of the resulting braided matrix with a first density. Next, in step 804, a second portion (e.g., rear portion of the double crown portion) of a hat form is moved at a second speed through a braiding machine to form a portion of the resulting braided matrix with a second density. If the first speed is slower than the second speed, this will result in a higher first density compared to the second density. Moreover, this process can be utilized at any location such that the speed of overbraiding (or the rate at which a hat form is pushed through the braided machine) is changed at any predetermined location to change the density of the resulting braided matrix.

In another embodiment, illustrated schematically in FIGS. 10-12, a hat form could be passed through a braiding machine twice in order to form hats with two layers (e.g., an inner layer and an outer layer). As seen in FIG. 10, the process may begin by pushing hat form 100 through braiding machine 102 in a first pass so that inner braid layer 1002 is laid down on hat form 100. In some embodiments, following the formation of a first braided layer, one or more supplemental structures (e.g., bands, reinforcing members, etc.) could be applied to inner braid layer 1002. In the exemplary embodiment shown in FIG. 11, bands 1102 and reinforcing members 1104 are placed against inner braid layer 1002. Next, as seen in FIG. 12, hat form 100 (covered with inner braided layer 1002) is pushed back through braiding machine 102 to apply outer braid layer 1202 over inner braid layer 1002. In some cases, a hat form is pushed through a braiding machine in a first direction to form the inner layer and then the hat form is pushed through the braiding machine in a second direction (opposite to the first) to form the outer layer. In some embodiments, the inner layer and the outer layer may be continuous, such that at least one strand extends through both the inner layer and the outer layer. This process allows for the two layer hats. Using additional layers may increase the strength and/or durability of the hats in some cases. In addition, in some cases, using two layers allows sweat bands, reinforcing members, and/or other components to be disposed between an inner and outer braided layer. Such a configuration may help keep these components in place and help reduce wear. Alternatively, in another embodiment, some components could be disposed between an inner and outer layer, while other components could be disposed on an inner most surface (e.g., a surface in contact with a head) of the final braided product.

FIGS. 13-16 illustrate schematic views of a method and system for manufacturing braided hats that have bills with two layers. Referring to FIG. 13, hat form 1300 may be similar in some respects to hat form 100 described above and shown, for example, in FIG. 1. For example, hat form 1300 includes double crown portion 1302 and double bill portion 1304. However, in contrast to hat form 100, the double bill portion of hat form 1300 is comprised of first bill portion 1310, first underbill portion 1312, second bill portion 1320, and second underbill portion 1322. In this case, first bill portion 1310 and second bill portion 1320 are configured to form upper braided layers of corresponding bills, and first underbill portion 1312 and second underbill portion 1322 are configured to form lower braided layers of corresponding bills.

As seen in FIG. 13, hat form 1300 may be moved through braiding machine 102 to form a braided structure around hat form 1300. The braided structure may be separated into two separate braided hats by cutting, melting, or another process. As an example, FIG. 14 is a top-down schematic view of an embodiment of first braided hat structure 1402 that has been formed. First braided hat structure 1402 includes braided crown portion 1410, braided over peak bill portion 1412, and braided under peak bill portion 1414.

It may be appreciated that braided over peak bill portion 1412 and braided under peak bill portion 1414 are formed continuously as hat form 1300 passes through braiding machine 102. Thus, as seen in FIG. 14, first braided strand 1430 extends continuously from braided over peak bill portion 1412 to braided under peak bill portion 1414, with first strand portion 1440 disposed in braided over peak bill portion 1412 and second strand portion 1442 disposed in braided under peak bill portion 1414.

FIGS. 15-16 illustrate optional finishing steps for making a braided hat with an under peak bill portion and an over peak bill portion. First, as seen in FIG. 15, braided under peak bill portion 1414 may be folded beneath braided over peak bill portion 1412. In some embodiments, an optional bill reinforcing member could be placed between the bill portions before folding. Next, in FIG. 16, finishing edge 1652 may be applied to lower periphery 1602 of braided hat 1600. Finishing edge 1652 is shown schematically in FIG. 16 and could comprise any of the methods discussed above for finishing edge 752, such as application of a TPU or hotmelt layer to sandwich the edges of the bill portion. In some cases, finishing edge 1652 may be used to fix braided under peak bill portion 1414 in place beneath braided over peak bill portion 1412.

FIGS. 17 and 18 illustrate schematic views of a braided article of headgear, or simply article 1700, according to an embodiment. Article 1700 may be formed using the overbraiding process described above and shown, for example, in FIGS. 4-7. For purposes of illustration, only some sections of braided construction 1750 of article 1700 are shown in FIGS. 17 and 18. However, it may be appreciated that the braided construction may comprise the entirety of the article in some embodiments. Additionally, though not shown here, some embodiments could include different regions of different braid densities. In some cases, regions of different braid densities could be formed using the process described above and shown in FIG. 8. Also, some embodiments could include two or more braided layers.

Referring to FIG. 17, article 1700 includes crown 1702 and bill 1704. Crown 1702 may further be associated with coronal plane 1710 and sagittal plane 1714. Crown 1702 further includes front portion 1720 disposed generally forward of coronal plane 1710 and rear portion 1722 disposed opposite of front portion 1720 such that rear portion 1722 is disposed generally rearward of coronal plane 1710. Crown 1702 further comprises left side portion 1724 disposed on one side of sagittal plane 1714, and right side portion 1726 disposed opposite of left side portion 1724, on the other side of sagittal plane 1714.

In the embodiments shown in FIGS. 17 and 18, strands of braided construction 1750 are seen to extend continuously across multiple portions of crown 1702. For example, as seen in FIG. 18, strand 1802 extends continuously from left side portion 1724 to right side portion 1726 of article 1700.

In FIG. 18, left side portion 1724 is seen to further comprise left base portion 1840 disposed proximate band 1805. Also, right side portion 1726 is seen to further comprise right base portion 1842 disposed proximate band 1805. Moreover, strand 1802 is seen to extend continuously from left base portion 1840 to right base portion 1842.

As seen in FIG. 18, second strand 1804 extends continuously from left side portion 1724 to right side portion 1726. Moreover, as seen in FIG. 18, second strand 1804 is shorter than strand 1802 due to its distinct position and path along crown 1702.

As seen in FIG. 18, third strand 1806 extends continuously from bill 1704 to left side portion 1724 of crown 1702. Moreover, fourth strand 1808 also extends continuously from bill 1704 to left side portion 1724, where fourth strand 1808 is slightly shorter than third strand 1806.

It may be appreciated that the features described for braided construction 1750 could also apply to headgear with multiple layers. For example, in some embodiments with two layers (e.g., the hat shown in FIG. 12), each layer may include at least one strand that extends continuously between sides of the hat. Also, in some cases, a single strand could extend continuously between the inner layer and the outer layer.

The exemplary embodiments provide articles of headgear (e.g., hats) with a continuous construction across different sides of the article. Thus, braided strands may extend from one side (e.g., left to right, or front to back) in a continuous manner to improve uniformity and limit detachment between sections, or panels, of a hat that might otherwise be stitched or glued together. This more uniform construction may also help improve fit and comfort as the various parts of the hat uniformly adapt to the shape and size of a wearer's head.

While various embodiments have been described, the description is intended to be exemplary, rather than limiting, and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of the embodiments. Accordingly, the embodiments are not to be restricted except in light of the attached claims and their equivalents. Also, various modifications and changes may be made within the scope of the attached claims.

Claims

1. An article of headgear having a crown; the crown having coronal plane, a transverse plane and a sagittal plane, the article of headgear comprising:

the crown with an interior void sized and configured to receive a wearer's head;

the crown comprising a front portion disposed generally forward of the coronal plane and a rear portion disposed opposite the front portion, the rear portion disposed generally rearward of the coronal plane;

the crown comprising a left side portion disposed on one side of the sagittal plane, and a right side portion disposed opposite the left side portion, on the other side of the sagittal plane;

the crown comprising a braided construction with at least one strand;

the strand extending continuously from the left side portion to the right side portion.

2. The article of headgear according to claim 1, wherein the crown includes a band disposed proximate an opening to the interior void;

wherein the left side portion includes a left base portion disposed proximate the band;

wherein the right side portion includes a right base portion disposed proximate the band; and

wherein the strand extends continuously from the left base portion to the right base portion.

3. The article of headgear according to claim 1, further comprising a bill attached to the crown.

4. The article of headgear according to claim 3, wherein the strand extends continuously from the bill to the left side portion.

5. The article of headgear according to claim 3, wherein the strand extends continuously from an under peak portion of the bill to an over peak portion of the bill.

6. The article of headgear according to claim 1, further comprising a second strand;

wherein the second strand is spaced from the strand;

the second strand extending continuously from the left side portion to the right side portion; and

wherein the second strand is shorter than the strand.

7. The article of headgear according to claim 6, further comprising a bill attached to the crown; and wherein the second strand extends continuously from the bill to the left side portion.

8. A hat form used to create an article of headgear, the hat form comprising:

a first side and a second side opposite the first side, wherein the first side is integrally formed with the second side;

the first side including a first crown portion;

the second side including a second crown portion;

wherein the first crown portion generally aligns with the second crown portion, thereby forming a double hat form; and

wherein the hat form is configured to be fed into a braid machine and receive an overbraided matrix of strands on its outer surface.

9. The hat form according to claim 8, wherein the first side includes a first bill portion connected to the first crown portion.

10. The hat form according to claim 9, wherein the second side includes a second bill portion connected to the second crown portion.

11. The hat form according to claim 10, wherein the first bill portion generally aligns with the second bill portion.

12. The hat form according to claim 9, wherein the first bill portion includes a first underbill portion extending from the first bill portion.

13. The hat form according to claim 10, wherein the second bill portion includes a second underbill portion extending from the second bill portion.

14. An article of headgear having a crown; the crown having coronal plane, a transverse plane and a sagittal plane, the article of headgear comprising:

the crown with an interior void sized and configured to receive a wearer's head;

the crown comprising a front portion disposed generally forward of the coronal plane and a rear portion disposed opposite the front portion, the rear portion disposed generally rearward of the coronal plane;

the crown comprising a left side portion disposed on one side of the sagittal plane, and a right side portion disposed opposite the left side portion, on the other side of the sagittal plane;

the crown comprising an inner braid layer and an outer braid layer.

15. The article of headgear according to claim 14, wherein the inner braid layer includes a strand strand extending continuously from the left side portion to the right side portion.

16. The article of headgear according to claim 14, wherein the outer braid layer includes a strand strand extending continuously from the left side portion to the right side portion.

17. The article of headgear according to claim 14, wherein the article of headgear includes a reinforcing member disposed between the inner braid layer and the outer braid layer.

18. The article of headgear according to claim 14, wherein the inner braid layer includes at least one strand and wherein the at least one strand extends continuously from the inner braid layer to the outer braid layer.

19. The article of headgear according to claim 14, further comprising a bill attached to the crown.

20. The article of headgear according to claim 19, wherein the inner braid layer and the outer braid layer extend through the bill.