SHAPE-HOLDING DEFORMABLE BRIM EXTENDER

Abstract

A brim extender attaches to any standard baseball-style cap and includes a malleable shape-holding portion that allows the user to deform portions of the brim extender to meet the sub-blocking and/or aesthetic needs of the user. Thus, the brim extender may provide advantages including (1) improved sun protection that may be customized by reconfiguring the shape of the brim extender, (2) additional options for style and appearance of the hat, (3) display of promotional items (e.g., a new thing that can be labeled, colored, or styled to market a brand), and/or (4) an added barrier between the head and the crown of the cap to shield or partially shield the cap from perspiration and other substances coming from the scalp or hair.

Description

BACKGROUND

Field

Improvements to baseball-style caps (or simply “baseball caps” or “caps”).

Description of the Related Art

Baseball-style caps have become very common throughout the world and are used for many purposes by men, women, and children. Such caps typically include a relatively stiff front brim or “bill” portion attached to a soft domed “crown” portion. They may be made of various solid or mesh fabrics, leather, or other such materials. The bill portion may be pre-shaped into an arched contour and is often reinforced with plastic or cardboard. The user can generally manually bend the bill portion to adjust the arch. The crown portion may be adjustable to fit heads of various circumferences. The adjustment device, usually in the posterior part of the cap is sometimes a strip of fabric or plastic, and may include a buckle device, Velcro, or other interlocking mechanism. Caps may also include an elastic headband portion to enable an adjustable fit or may not have a size adjustment feature. Although referred to here as “baseball-style caps,” we use this term to describe a wide variety of similar caps that may be referred to in the marketplace as golf caps, trucker hats, fitted caps, snap-back caps, and other such terms that all describe hats made of various materials that consist of a crown and frontal brim.

Once used primarily by baseball players, such caps are now used in many other sports, workplaces, and recreational environments. They are often also manufactured and sold as promotional items, meaning that a business or team may print a logo and/or use a color scheme on the hat that helps promote a particular brand. Logos may be embroidered, printed, or otherwise attached to the cap. Despite the wide number of purposes for baseball-style caps and the large number of manufacturers, such caps have a relatively common shape.

SUMMARY

Baseball-style caps afford some head and facial sun protection, but may not adequately shade the ears, side of the face, or back of the neck. Thus, disclosed herein are improvements to baseball-style caps in the form of an attachment that may serve one or more functions, including: (1) extending sun protection along the sides and posterior portion of the hat, (2) changing the style and appearance of the hat, (3) providing a new promotional item (e.g., a new thing that can be labeled, colored, or styled to market a brand), and/or (4) providing an added barrier between the head and the crown of the cap to shield or partially shield the cap from perspiration and other substances coming from the scalp or hair. The invention also includes an attachment, generally referred to as a “brim extender” herein, designed for a baseball-style cap that may be sold in conjunction with a matching baseball cap.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a person wearing a baseball cap with a brim extender attached thereto.

FIG. 2A illustrates a cap and a brim extender.

FIG. 2B is a bottom view of the cap and brim extender with a portion of the bill extending through the slit in the brim extender.

FIG. 2C is a top view of the cap with the brim extender attached via insertion of the bill through the slit of the cap.

FIG. 3A is a top view of a hat prior to attachment of the brim extender.

FIG. 3B is a bottom view of the cap and brim extender with a portion of the bill extending through the slit in the brim extender.

FIG. 3C is a top view of the cap with the brim extender attached via insertion of the bill through the slit of the cap.

FIG. 4A is a top view and FIG. 4B is a perspective view of another example brim extender.

FIGS. 5A-5I are a series of representations of the brim extender being attached to a cap.

FIG. 6 illustrates the cap with the brim extender attached, ready for use by a wearer.

FIG. 7 illustrates a two layer brim extender, including layers and.

FIG. 8 illustrates an example manufacturing environment that may be used to manufacture brim extenders.

FIG. 9 illustrates another example embodiment of a brim extender that includes two attachment slits.

FIG. 10 illustrates another example of a brim extender with a malleable shape-holding member.

FIG. 11 illustrates an example of layers of a brim extender, including a top layer, a bottom layer, and a malleable shape-holding member interspersed between.

FIGS. 12A-12C illustrate an example brim extender attached to a baseball cap, with the brim extender in three different configurations that are generally held in place by a malleable shape-holding member.

DETAILED DESCRIPTION

FIG. 1 illustrates a person or user 160 wearing a baseball cap 100 with a brim extender 110 attached thereto. In this example, a bill 101 extends ahead of a wearer 160 to provide some shade on the wearer's face. The brim extender 110 advantageously enhances the overall sun protection of the combined cap/brim extender apparatus by providing additional shade to the sides and back of the users face and neck.

FIG. 2A illustrates a cap 200 and a brim extender 210. The cap includes a bill 201 and crown 202 portions. The crown 202 includes an adjustment device 220, which may include an interlocking mechanism, a buckle, hook and loop material, and/or other material that allows a sized of the crown 202 to be adjusted (e.g., to fit larger or smaller heads). The bill 201 may be a relatively stiff material while the crown 202 may be a more flexible material configured to fit on a person's head. For example, the bill 201 and crown 202 may be made of foam, plastic, leather, and/or other materials. In the example of FIG. 2A, the brim extender 210 is configured to attach to the cap 200 to provided one or more of the advantages noted above. For example, the brim extender 210 may provide additional protection from the sun, beyond the shading provided by the bill 201 and crown 202 of the cap 200.

In the example of FIG. 2A, the brim extender 210 is shaped to enable attachment to the cap 200 without strings, tape, glue, or mechanical fasteners. In this embodiment, the brim extender 210 includes an “under the crown” portion 212 (e.g., including the multiple tabs 213 in the example of FIG. 2A) configured to fold between the crown 202 of the cap 200 and the head of a wearer. Depending on the embodiment, this under the crown portion 212 may be of various shapes and sizes. For example, the under the crown portion 212 of the brim extender 210 includes several tabs 213 that are divided with slits in material of the brim extender 210, while the under the crown portion of the brim extender 310 (FIG. 3A) includes four tabs 313 spaced apart by larger openings (e.g., material that is removed during the manufacturing or assembly process), and an under the crown portion of the brim extender 410 (FIG. 4A) includes a single tab under the crown portion 412. Other variations in the under the crown portion of the brim extender are contemplated, such as to include any other quantity, shape, spacing, etc. of tab portions.

Returning to FIG. 2A, the brim extender 210 also includes a slit-like opening 214 configured to enable passage of the bill 202 of the baseball cap 200 such that a portion 216A of the brim extender 210 comes to lie above the brim. A shading portion 216 also extends outward around the sides and back of the crown 202 when worn by a wearer, while the under the crown portion 212 folds between the crown 202 and the wearer's head. This combination of “over the bill” and “under the crown” portions of a single continuous attachment enables the brim extender 210 to remain in position when worn, while still being easily removable when desired. In some embodiments, the brim extender 210 may include one or more fixation device, such as a clip, pin, hook and loop material, and/or glue, to provide further attachment of the brim extender 210 and the cap 200. In the example of FIG. 2A, no additional fixation device is used to keep the brim extender 210 in proper position.

The brim extender 210 may vary in shape, such as smooth contour or jagged contour. In some embodiments, the brim extender 210 is a relatively flat sheet of material, or may be made of a material that simulates appearance of human hair, for example. Portions of the bill extender 210 may be labeled via embroidering, printing, or other-attachment. As discussed further below with reference to FIG. 8, brim extenders may be manufactured from a single flat piece of plastic, foam, fabric, rubber, neoprene, leather or other such substance, or produced from a variety of substances that are sewn or otherwise bonded together (see, e.g., FIG. 7). Brim extenders may be sold as standalone products (e.g., for attachment to a cap of the purchaser's choice) and/or may be packaged with a cap (e.g., with a similar color, style, etc.). The design could be incorporated into a new and distinct style of baseball cap.

FIG. 2B is a bottom view of the cap 200 and brim extender 210 with a portion of the bill 201 extending through the slit 214 in the brim extender 210. As shown, the tabs 213 are configured to be pressed into the crown 202 of the cap 200 when placed on the head of a wearer, such that compression of the tabs 213 between the wearer's head and the crown 202 of the cap maintain position of the brim extender 210 with reference to the cap 200. FIG. 2C is a top view of the cap 200 with the brim extender 210 attached via insertion of the bill 201 through the slit 214 of the cap 200. As shown, with the brim extender 210 attached in this manner, the area of shading provided to a wearer is significantly increased.

FIG. 3A is a top view of a cap 300 prior to attachment of the brim extender 310. As noted above, the brim extender 310 includes four tabs 313 configured to fit between a head of the wearer and the crown 302 of the cap 300. FIG. 3B is a bottom view of the cap 300 and brim extender 310 with a portion of the bill 301 extending through the opening 330 in the brim extender 310. As shown, the tabs 313 are configured to be pressed into the crown 302 of the cap 300 when placed on the head of a wearer. FIG. 3C is a top view of the cap 300 with the brim extender 310 attached via insertion of the bill 301 through opening in the brim extender 310. In this example, the brim extender 310 includes a larger front shading portion 311 that extends forward beyond the length of the bill 301. In other embodiments the length of the front portion 311 may be even larger. Similarly, the length of side and rear portions of the brim extender 310 may be larger or smaller in other embodiments.

FIG. 4A is a top view and FIG. 4B is a perspective view of another example brim extender 410. In this example, the under the crown portion includes an attachment tab 413 configured to fit through an attachment slit 414 to attach the brim extender 410 to a cap. In particular, an expanded portion 413A of the tab 413 is wider than the slit 414 so that once the tab 413A is through the slit (e.g., by manually compressing the expanded portion 413A as pushing through the slit 414), the expanded portion 413A maintains the attachment of the tab 413 around an adjustment device 220 (e.g., as shown in FIG. 2A) of a cap. In the example of FIGS. 4A and 4B, the brim extender 410 also includes adhesive tabs 415 configured to further secure the brim extender 410 to the bill of the cap 400. In some embodiments, there may be none, one, or more than two tabs 415. In some embodiments, the tabs may include a hook-and-loop type fastener, such as Velcro, or a similarly adherent fabric rather than an adhesive material. The tabs may be configured to attach to a corresponding hook-and-loop type fastener (e.g., Velcro) or a similarly adherent fabric that is glued or sewn to the undersurface of the bill. In some embodiments, the undersurface of the brim may have strips of Velcro or a similarly adherent fabric sewn or glued to it to attach the upper surface of Velcro strips or a similarly adherence fabric that are sewn or glued to upper surface of the bill of the cap.

In another embodiment, the attachment tab 413 may not pass through a slit but instead pass through a retaining strap or keeper that is sewn in the approximate position of slit 414. In one embodiment that attachment tab 413 does not have an expanded end, but instead has a fold or seam that loops under a retaining strap or keeper. In another embodiment, the attachment tab 413 may slide between the crown of the cap and the user's head to keep the cap in place. In another embodiment, tab 413 or an equivalent tab may contain Velcro or a similarly adherent fabric (e.g., any fabric that contains hooks) that attaches to a strip of Velcro or a similarly adherent fabric that is sewn or glued to the undersurface of the crown of the cap in a matching position.

FIGS. 5A-5I are a series of representations of the brim extender 410 being attached to a cap 400. Beginning with FIG. 5A, the cap 400 is shown separate from the brim extender 410. As noted above, the brim extender 410 may be acquired (e.g., as a gift or purchase) separately from the cap 400 or may be packaged with the cap 400. In FIG. 5B, a user removes a backing material 416 from one of the tabs 415. A similar process may be performed on the other tab 415 to expose an adhesive material on the tabs 415. In this example embodiment, the adhesive on the tabs 415 adhere to a bottom side of the bill 401 to provide a more secure connection between the brim extender 410 and the cap 400. Continuing to FIG. 5C, the bill 401 of the cap 400 is inserted into the opening 430. FIG. 5D illustrates the tabs 415, with the adhesive surface exposed, being pushed under the bill 201. FIGS. 5E-5H illustrate the bottom side of the cap while attaching the attachment tab 413 around an adjustment device 420 of the cap 400. As show in FIG. 5H, with the attachment tab 413 wrapped around the adjustment device 420 of the cap 400, the expanded portion 413A extends through the slit 414 and maintains the tab 413 around the adjustment device 420 of the cap. FIG. 5I illustrates a user depressing the adhesive tabs 415 onto the bottom surface of the bill 401. FIG. 6 illustrates the cap 400 with the brim extender 410 attached, ready for use by a wearer. In one embodiment, user instructions may be printed on the brim, such as along the underside of the posterior portion of the brim, or the instructions may be attached as a bonded or sewn-on label.

FIG. 7 illustrates a two layer brim extender 710, including layers 712 and 714. In this embodiment, the layers 712 and 714 may comprise the same or different materials and may provide the same or different functionalities. For example, one of the layers may be a more rigid backing or interfacing material while the other layer may be a softer or elastic material. In one example, layer 712 is a semi-stiff backing bonded or sewn to a printable, flexible and/or elastic fabric 714. In one embodiment, the brim extender may include two layers, in which one of the layers is a somewhat stiff backing or interfacing fabric (such as buckram, Pellon®, plastic) and another layer is made of an elastic fabric, with the elastic fabric's inner perimeter forming an smaller oval shape than the backing material. As a result, the elastic fabric may help keep the brim extender in place by stretching around the crown of the cap. In one embodiment, the brim extender may include an elastic band that is sewn or bonded along the inner perimeter of the brim extender. In one embodiment, the brim extender contains three layers, with a backing fabric layered between two elastic fabrics of different color or style, so that the brim extender can be worn with either side facing upward. In one embodiment, a portion of the brim extender may be attached to the bill of the cap using a plastic or metal clip, such as a decorative paper clip or golf ball marker clip. Thus, in some embodiments, an inner perimeter of the brim extender 710 that fits around the cap crown is stretchable, and also, the upper and/or lower surface of the brim is printable or any portion of the brim may be embroidered and have a label sewn-on. The layers may be bonded together in any manner, such as via an adhesive. Multiple layers may be used in any of the other brim extender embodiments discussed herein.

FIG. 8 illustrates an example manufacturing environment that may be used to manufacture brim extenders. In this example, a roll of material (e.g., single or multi-layer foam or material) 810 is receiving by a stamping machine 820 configured to pull the material through the machine 820 and to stamp (or otherwise cut-out) multiple brim extenders 830. The process may be entirely or partially automated, such that the brim extenders 830 may be easily manufactured in bulk. In this example, broken lines of the brim extenders 830 show the cuts in the material 810. In some implementations, the machine 820 may also include a marking component configured to print, spray, iron-on, or otherwise apply coloring to the brim extenders 830, such as to provide an advertising or marketing message on each of the brim extenders 830. In some embodiments, the material 810 is pre-marked with such marketing information, so that when the space of the brim extenders 830 is cut from the material, the advertising is appropriately positioned on the brim extenders 830.

FIG. 9 illustrates another example embodiment of a brim extender 900, in this example, the brim extender 900 includes two attachment slits 902. The attachment tab 903 may be better held in place when intertwined with the attachment slits 902, such as positioned through one of the attachment slits 902 in a first direction and through the second of the attachment slits 902 in a second direction. The use of two attachment slits may result in the tab remaining substantially on the undersurface of the brim except for the portion of the tab that lies between the two slits.

FIG. 10 illustrates another example of a brim extender 920. In this embodiment, the brim extender includes a malleable shape-holding member 922 configured to allow the user to deform the brim extender 920 to a desired shape and to hold the desired shape while the brim extender 920 is worn. The malleable shape-holding member 922, which may also be referred to as a memory wire, may comprise various materials, such as a millinery wire (e.g., a 16, 19, or 23 gauge millinery wire), galvanized steel covered with cotton, rayon or paper, polypropylene, steel spring wire, or other material that has similar shape-holding properties.

In the example of FIG. 10, the shape-holding member 922 is attached to a bottom surface of the brim extender, such as by an adhesive or sewing. In some embodiments, the shape-holding member 922 may be attached to at least a portion of a peripheral margin of the brim extender by sewing it under an elastic or non-elastic binding tape and/or any other strip of material that may be folded over the brim's outer margin. In other embodiments, a shape-holding member 922 may be held in place between layers of a multi-layer brim extender, such as is shown in the example of FIG. 11, which illustrates an example of a brim extender including top layer 950 and a bottom layer 954, with a malleable shape-holding member 952 interspersed between.

Advantageously, addition of the malleable shape-holding member 922, e.g., along the peripheral margin and/or at other positions of the brim extender, may allow the brim extender to be shaped to conform to the curve of the bill of the cap. Additionally, the malleable shape-holding member allows the brim extender to be shaped to a style that is desired by the user (e.g., cowboy style, bucket style, etc.). The malleable shape-holding member 922 may also provide a more rigid perimeter that allows the brim extender to stay on the cap without other fixation device, or with less other fixation device, such as only a posterior tab.

The shape-holding member be uniformly positioned around a perimeter of the brim extender, or at some uniform distance from an outer edge of the brim extender. In some embodiments, the shape-holding member may not to uniformly distanced from the outer edge. Additionally, the shape-holding member may extend only around a portion of the circumference of the brim extender, such as leaving a back portion of the brim extender without the shape-holding member. In some embodiments, the shape-holding member comprises multiple wires and/or other shape-holding materials. For example, in one embodiment a first shape-holding member extends around an outer circumference of the brim extender and a second shape holding member extends around only a front portion of the brim extender near an inner circumference of the brim extender to provide additional deformation options in the front of the brim extender. In some embodiments, the shape-holding member may comprise multiple materials that are positioned radially or in other locations.

The brim extender may be made of material (or materials) suitable for dye sublimation or print-screen printing such as, for example, a layer of neoprene (e.g., bottom layer 954) bonded to nylon fabric (e.g., top layer 950).

In some embodiments, a brim extender may be formed of a malleable shape-holding material, rather than or in addition to, a shape-holding member (e.g., a malleable wire). For example, a single or multi-layer substrate may itself have shape-holding properties.

FIGS. 12A-12C illustrate an example brim extender attached to a baseball cap 962, with the brim extender in three different configurations that are generally held in place by a malleable shape-holding member. For example, FIG. 12A shows the brim extender 960 arranged in a first configuration with a right side 960 deformed upward with the left side 961 remaining relatively horizontal, FIG. 12B shows the brim extender 960 in a second configuration with both sides 960 and 961 curved upward, and FIG. 12C shows the brim extender 960 in a third configuration with a front 964 curved upward. Advantageously, the same brim extender 960 provides the user with limitless configurations that best serve the user's sun protection, aesthetic, and/or other needs.

Example Implementations

The systems, methods, and devices described herein each have several aspects, no single one of which is solely responsible for its desirable attributes. Without limiting the scope of this disclosure, several non-limiting features will now be discussed briefly. The following paragraphs describe various example implementations of the devices, systems, and methods described herein.

In one example, a brim extender comprises a first layer that may include a substantially stiff backing material and having a first central aperture sized to receive a crown portion of a baseball cap, a second layer that may include a fabric having a second central aperture sized to receive the crown portion of the baseball cap, and a malleable shape-holding member, wherein the first and second layer are bonded or sewn together, with the malleable shape-holding member therebetween, where the malleable shape-holding member is positioned near outer circumferences of the first and second layer so that a manual deformation of a portion of the brim extender by a user is maintained.

Implementations may include one or more of the following features. The brim extender where the malleable shape-holding member may include a millinery wire. The millinery wire is in the range of 16 to 23 gauge. The malleable shape-holding member may include galvanized steel covered one or more of cotton, rayon or paper. The malleable shape-holding member may include polypropylene. The malleable shape-holding member may include steel spring wire. The malleable shape-holding member extends around at least a portion of the first central aperture near the outer circumference of the first and second layers. The malleable shape-holding member extends around the entire outer circumferences of the first and second layers. The first layer may include neoprene. The second layer may include nylon fabric. The brim extender may include: a second malleable shape-holding member. The second malleable shape-holding member is positioned inward of the malleable shape-holding member. The second malleable shape-holding member extends radially from near an inner circumference of the first and second layers towards the outer circumferences of the first and second layers. At least one of the first and second layers form: an attachment tab extending into the first and second central apertures; and an attachment slit sized and positioned to allow a portion of the attachment tab to pass therethrough.

In another example embodiment, a brim extender may include a substantially oval or circular shaped substrate that includes a central aperture sized to receive a crown portion of a baseball cap; and a malleable shape-holding member attached to the substrate near an outer edge of the substrate, the malleable shape-holding member configured to retain manual deformations of the malleable shape-holding member and a corresponding attached portion of the substrate.

Implementations may include one or more of the following features. The brim extender where the malleable shape-holding member is glued or sewn to the substrate. The substrate includes at least two layers bonded or sewn together with the malleable shape-holding member held in place therebetween.

In another example embodiment, a method of manufacturing a brim extender may include positioning a malleable shape-holding member between a first layer may include a substantially stiff backing material and a second layer may include a fabric, where each of the first and second layers include a central aperture sized to receive a crown portion of a baseball cap; and bonding or sewing the first layer to the second layer so that the malleable shape-holding member is positioned near an outer circumferences of the first and second layers.

Claims

1. A brim extender comprising:

a sheet of material with a central aperture sized to fit over the crown of a baseball-style cap; and

a malleable shape-holding member attached at or near a peripheral margin of at least a portion of the periphery of the brim extender;

wherein the malleable shape-holding member is configured to retain manual manipulations of the brim extender.

2. The brim extender of claim 1, wherein the malleable shape-holding member comprises a wire.

3. The brim extender of claim 2, wherein the wire is in the range of 12 to 23 gauge.

4. The brim extender of claim 1, wherein the malleable shape-holding member comprises polypropylene.

5. The brim extender of claim 1, wherein the malleable shape-holding member comprises one or more of a malleable metal, steel, or copper.

6. The brim extender of claim 1, wherein the malleable shape-holding member is sewn to the brim extender

7. The brim extender of claim 1, wherein the malleable shape-holding member is sewn to the brim extender by enclosing it within an elastic or non-elastic fabric binding that is sewn or glued at or near the periphery of the brim extender.

8. The brim extender of claim 7, wherein the periphery of the brim extender comprises at least a generally semicircular outer circumference of the sheet of material.

9. The brim extender of claim 1, wherein the malleable shape-holding member extends around the entire outer circumferences of the sheet of material.

10. The brim extender of claim 1, wherein the sheet of material comprises at least two laminated sheets.

11. The brim extender of claim 10, wherein at least one of the sheets is suitable for printing.

12. The brim extender of claim 1, further comprising:

one or more tabs comprising an attachment component configured to adhere to the baseball-style cap.

13. The brim extender of claim 12, wherein the one or more tabs comprises an adhesive.

14. The brim extender of claim 12, wherein the one or more tabs comprise a hook-and-loop fastening material.

15. The brim extender of claim 14, wherein the hook-and-loop fastening material is positioned to adhere to a corresponding hook-and-loop fastening material in a matching portion of the baseball-style cap.

16. The brim extender of claim 1, further comprising an adhering material located along the undersurface of the sheet of material and is configured to adhere the sheet of material to a similar material located on an upper portion of a bill of the baseball-style cap.

17. The brim extender of claim 12, wherein the attachment component is located along an upper surface of at least one tab and is configured to attach to similar attachment material along an undersurface of a crown of the baseball-style cap.

18. A brim extender comprising:

a substantially oval or circular shaped substrate comprising a central aperture sized to receive a crown portion of a baseball cap; and

a malleable shape-holding member attached to the substrate near an outer edge of the substrate, the malleable shape-holding member configured to retain manual deformations of the malleable shape-holding member and a corresponding attached portion of the substrate.

19. The brim extender of claim 18,

wherein the malleable shape-holding member is glued or sewn to the substrate.

20. A method of manufacturing a brim extender comprising:

positioning a malleable shape-holding member between a first layer comprising a substantially stiff backing material and a second layer comprising a fabric, wherein each of the first and second layers include a central aperture sized to receive a crown portion of a baseball cap; and

bonding or sewing the first layer to the second layer so that the malleable shape-holding member is positioned near an outer circumferences of the first and second layers.