US 3358292 A
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Dec. 19, 1967 C. BONK ET AL CAP Filed April 9, 1965 2 Sheets-Sheet 1 0 W KM 5 G. NFHW In mm. M @WAMM Dec. 19, 1967 c. BONK ET AL CAP 2 Sheets-Sheet 2 Filed April 9, 1965 INVENTOR CHA m4 Bo/wr 6,4 M 4/51. PA F0 w/rz TTORNEY United States Patent This invention relates to an improvement in caps and particularly to caps having ear flaps designed to cover the ears and a portion of the head.
It is an object of this invention to provide a cap in which the so-called ear flaps are continuous so as to encircle the head around the ears from one temple to the other.
It is a further object of the present invention to provide ear flaps of a particular shape structurally and of a resilience so as to snugly engage the back of the head and sides of the head along their unattached terminal edge.
It is a further object of the present invention to provide an outer flap to encircle the skirt portions of the cap which may be unfolded to overlie the unfolded ear flap so as to hold the ear flaps in snug relation to the head and at the same time provide additional warmth and comfort.
It is a further object of the present invention to provide a cap having the aforementioned advantages in which the cap may be provided either with or without a vizor as desired.
It is a further object of the present invention to provide a cap in which the structural relationship of the outer band to the front portion of the cap is such that when the outer band is unfolded over the ears that the cap deformed to more snugly fit the head of the person wearing the cap.
We have discovered that although it is possible to provide the stretch member along the terminal edge of the ear flaps to improve the snug relationship of the flaps to the back and sides of the head, yet in some instances because of the variation in head sizes the snug fit is not achieved as adequately as desired. We have also noted that while it is possible to construct caps in certain sizes which will adequately accomplish the task for which they are manufactured, yet because of the variations in head sizes a tremendous stock of caps must be maintained to accomplish. In order to alleviate the difiiculty of the manufacturer and the retailer in storing large quantities of caps, various attempts have been made to provide caps which will fit multiple sizes of heads. In general, this is accomplished by providing some form of resilience in the structure of the cap. Admittedly, the use of multi-sized caps has been a boon to the cap making industry in that the requirements of huge stocks have been markedly reduced. However, while there has been an advantage gained by reducing the size of the stock, an obvious disadvantage has arisen in that caps which are designed to fit a multiple of sizes tend to provide gaps along the sides of the head which they are designed to fit in some instances or to be too binding in other instances.
The present invention is designed to provide a structure in which the relationship of the various parts does not cause the binding mentioned heretofore, and at the same time by providing a unique structure, the gaps are eliminated.
It is a further object of the present invention to provide a cap which is particularly attractive, and which may be manufactured at a reasonable price.
It is a further object of the present invention to provide a cap in which a modified outer brand may be employed to eliminate part of the tightness which otherwise tends to occur because of the variance in head shapes.
These and other objects and particular advantages will be more fully described in detail in the accompanying "ice specifications taken in connection with the drawings here with in which FIGURE 1 is a perspective view of the cap;
'FIGURE 2 is a side elevation showing the ear flaps in an unfolded position.
FIGURE 3 is a view taken from front to rear of the cap of FIGURE 2 illustrating the generally concave shape of the ear flaps.
FIGURE 4 is a side elevation with the outer band in an unfolded position overlying the ear flaps, the ear flaps being shown in dotted outline.
FIGURE 5 is a view taken from front to rear of the cap shown in FIGURE 4.
'FIGURE 6 is a sectional view showing the structural relationship of the cap.
FIGURE 7 is a view of a modified outer band.
FIGURE 8 is an enlarged section of the cap of FIG- URE 7 to illustrate the structural relationship of a cap having the modified band.
FIGURE 9 is a perspective view of a cap having the modified outer band.
FIGURE -1 of the drawings illustrates a cap generally numbered 10 having a crown 12 from which depends skirt portions to provide the body of the cap. The front portion which depends from the crown is numbered 14 for purposes of description, the back portion is numbered 16 and the side portions 18 and 20 respectively. It will be understood that the back, front, and side portions are c011- nected together to form a continuous cap together with the crown.
In the preferred construction shown in FIGURE 1 the depending portions are connected to the crown 12 by a seam 22. The crown may be of any desired shape, but in general would be of a normally oval or round shape. As the cap body is quite similar in outer appearance to other caps, it is believed that no further description is necessary for understanding.
The depending skirt portions terminate in a substantially continuous edge along a substantially common plane.
An elongated ear flap 24 is foldably connected adjacent the continuous edge of the cap body. The ear flaps as will be understood, vary in depth according to the portion of the head to be covered. If desired, the ear flap may extend so as to cover a portion of the forehead at least. However, this would be obvious, and is not believed necessary to be further described.
FIGURE 6 illustrates the preferred form of construction in which the relationship of the ear flap to the inner portion of the cap may be seen.
The ear flap is stitched along a seam 26 to the depending side and rear skirt portions.
As may be seen in FIGURE 3, the elongated continu ous flap 24 is generally concave so as to snugly fit the back of the head and to cover the ears of the head. The ear flaps may be of any desired resilient material which can be contoured to provide the desired structure. In the preferred construction a sponge plastic material is laminated to a stretchable outer material to provide desired warmth, durability, and fabric qualities. The stretchable outer material may be vertically ribbed to stretch in a longitudinal direction more than in a transverse vertical direction. Obviously, a wide variety of laminates will accomplish this purpose, one of the better choices being that of a nylon outer covering laminated to the sponge material. It Will be understood that both the sponge material and the covering must be adapted to stretch in a longitudinal direction, and self ability to stretch in a transverse direction is not objectionable. The ear flap is secured in tightly gathered relation along the seam 26 to the depending skirt portions. Because of the generally la oval or circular shape of the cap, the ear flap tends to assume a concave shape. In the preferred construction this concave shape is further induced by stitching along the lower edge 28 of the flap 24.
As will be understood with the ear flap portion in a. concave shape, the flap will conform readily to the shape of the back of the head as well as providing a receptacle in which the ears are covered. Because of the shape, the flap snugly fits against the back and sides of the head on which it is placed. To increase the snuguess of the preferred cap, a stretch member 30 is provided which extends along the free terminal edge of the ear flap from a point adjacent the front of the cap around to the other front portion of the cap. The stretch member 30 is held in desired position of the flap 24 by stretchable stitching 32 which may be a knitted or woven effect. The stitch should be able to allow the stretch member to extend and contract in conformance to the head on which the cap is being worn. The stretch member 30 and tightly gathered seam 26 hold the fiap 24 generally concave.
As may be seen in FIGURE 6, the cap will normally have an outer material which may be nylon, corduroy, or any other suitable fabric or laminate. This outer fabric has been generally numbered 34. A lining 36 is provided which conforms to the shape of the cap and extends throughout the cap interior. In some instances, the lining is placed only on the front portion of the cap interior and on the crown, and in other instances on the crown alone depending on the type of fabric being used in the cap construction. In other words, if a somewhat loosely knit stretchable material is used, the lining might be used only on the crown, whereas, in a cap of a stiffer material, the lining might be employed all the way around the cap interior. As this is a common expedient of the trade, it is not believed to be in need of further description.
In the cap of FIGURE 6, at least a portion of the sides and back is comprised of a stretchable material so as to enable the cap to fit a variety of head sizes. The stretch material extends along a common plane from the crown in a depending relation. In the preferred construction, the stretchable material employed in the skirt portion is continuous. In other words, while it would be possible to use inserts of stretchable material, the preferred construction utilizes only one such continuous band of stretch material. The stretchable material is preferably more stretchable in a longitudinal direction than in a transverse direction for obvious reasons. This stretchable portion of the cap body may be formed of two layers of knitted material or of a combination of knitted and foam material laminated together, or of any other suitable material which will provide the desired stretchability. The material obviously must be resilient in order to retain its shape.
a As may be seen in FIGURE 4 the knitted or stretchable depending skirt portions are secured along a common plane adjacent the crown by stitching 38.
As may be seen in greater detail in FIGURE 6, the preferred construction employs a non-stretching depending portion secured to the crown along the seam 22 and extending downwardly to provide an edge 40 along a common plane to which the stretchable side and back portions are secured by stitching such as 38.
In the preferred construction an outer band 44 is provided which is foldable to overlie the side and back portions of the cap body and unfoldable to overlie the earflap flaps. This construction may be seen in FIGURES 2 and 4. As may be seen in FIGURE 2, the outer band is secured at a point along the terminal edge of the front portion of the cap, this point being numbered 46 with the other end of the band being secured at a point 48. As the outer flap is unfolded to overlie the earflaps, the outer band tends to deform the cap body along a somewhat curvilinear line which corresponds generally to the edge 56 of the depending skirt portions of the cap.
In the event that a vizor 52 is provided, the portions of the band which overlie the vizor in an unfolded con- A, dition tend to deform the vizor so as to provide a concave outline of the vizor.
In the preferred construction, which may be observed in FIGURES 2 and 5, theouter band has a generally concave shape in both the folded and unfolded positions. In the folded positions in which it overlies the sides and back of the cap body, this concave outline insures a neat appearance of the cap, and when the outer band is unfolded to overlie the earfiaps, the outer band serves as an additional warm member and additionally holds the earflaps snugly against the sides of the head and as well tends to conform the forward portion of the cap to fit the temples.
For those who have encountered the rigors of northern winters particularly where wind is a factor, the marked advantage of this construction will be appreciated.
To increase the ability of the outer band to conform to the shape of the back of the head and sides of the head along its terminal edge, a stretch member 54 which is similar to the stretch member 30 is provided, the mem: ber 54 being held in desired position along the terminal or free edge of the outer band 56 by stitching, knitting, or overlaying of material 58.
It is obvious as has been previously mentioned, that a vizor may be employed or omitted as desired in the cap construction while still obtaining the advantages of the structure.
In a modified form of outer band shown in FIGURE 7, the outer band is secured to the front portion of the cap from a point adjacent the temples numbered 60 to a point further along the front such as 62. The remainder of the outer band is unsecured enabling the outer band to be moved lower on the back of the head and neck as desired when unfolded, and when folded to be returned to the position shown in FIGURE 9. In the modified structure of FIGURES 7 and 9, the entire outer band need not be of a stretchable material inasmuch as the ends 64 and 65 of the outer band are secured to the front of the cap and accordingly the stretch will be from the forehead to the back. Therefore, it is possible to utilize an outer band in which only a portion of the band is of stretchable material. This enables the cap to be made with a material similar to the material of the front for the portions ofthe outer band with the back being of stretchable material as has been previously described.
FIGURE 7 additionally shows more clearly the seam line 38 along which the side and back portions of the stretch material are secured in the preferred construction previously described.
FIGURE 8 illustrates the preferred form in constructing the modified outer band of FIGURE 7. The flap 24 is secured by stitching 26 to the skirt portion 64 which may be the liner and stretchable depending skirt or the skirt alone depending on whether or not a liner is used. Obviously one or more layers of the stretchable material may be used as desired. The modified outer band 66 overlies the skirt portion 64. As previously indicated, the outer band is stretchable so that it conforms to the outer shape of the cap body.
It is important to note that in the desired cap construction, the particular arrangement of the ends or edges of the material is preferred in order to provide a cap of particular shape to avoid undue bulk. This is achieved by a staggering of the points at which seam connections are made. In other words, it is to be noted that the stretch member 30 is positioned intermediate the folded edge 68 of the outer band and the other edge or seam connections. Additionally, the seam line 26 is at a different point preferably than other folded edges or seams. The stretch member 54 is above the seam connection 42 and the stitched line 22 is at a different elevation from the stretch line 70 at which the liner is connected to the depending skirt. This is a particularly unique construction which has heretofore been impractical because no way could be found to have the outer band fold snugly against the outside of the cap while earflaps assume the same snug position inside the cap. The concave shape of the outer band and the earflaps enable the advantageous connection of the parts.
Returning to FIGURE 6, the vizor 52 may be of layered construction having a center member 72 covered by any desired covering material 74 and 76. Preferably, the vizor joins the front of the cap adjacent the planer edge previously described being held in secured relation by suitable stitching as indicated at 78. The depending front portion where a vizor is employed is inturned to provide a deep seam line of stitching.
As may be seen in FIGURE 6 a double layer of covering material and laminate may be employed to provide similar facings on both sides of the earfiaps. In this instance the layers in face to face abutting relation, are of the spongy laminate with the outer facing materials being of any desired choice as nylon, cotton, plastic, etc. The double layers have been indicated as numbers 80 and 82 for purposes of description. As previously indicated, one would not need to provide such double layers if a more inexpensive construction or less warmth were to be desired.
It will be understood that the crown 12 may be of a relatively inelastic material as may also be the front 14. On the other hand, if desired, all of the cap body may be of an elastic or resilient material. However, our particular construction enables the choice of materials in relation which have not previously been possible.
In accordance with the Patent Statutes, while we have set forth the best embodiments of our invention, we desire to have it understood that obvious changes and modifications may be made within the scope of the accompanying claims without departing from the spirit of our invention.
1. A multiple sized cap comprising:
(a) a crown,
(b) resilient front, rear, and side portions having inner and outer surfaces depending from said crown adapted to generally encircle the head of a person,
(c) said front, rear, and side portions having lower edges forming a substantially continuous edge along a substantially common plane,
(d) an elongated resilient vertically-ribbed ear flap in overlying relation to said inner surfaces of said rear and side portions, and being stretchable to a greater extent longitudinally than transversely,
(e) a tightly gathered seam marginally securing said earflap marginally upward from the lower edges of said rear and side portions,
(f) the marginal free edge of the earflap including a resilient stretch member,
(g) an elongated resilient outer band having a lower edge and forward ends in overlying relation to said rear and side portions,
(h) said outer band secured at the lower edge of each forward end to the lower edge of said front portion with the remaining portion of said outer band lower edge being free of attachment,
(i) said tightly gathered seam and said resilient member of said earflap normally holding said earflap concavely contoured to snugly embrace the sides and back of a persons head when unfolded with said outer hand optionally unfoldable in overlying relation to said earflap.
2. The structure of claim 1 and in which the other edge of said outer band includes a resilient member.
3. The structure of claim 1 and in which:
(a) a vizor is secured along the lower edge of said front portion,
(b) said ends of said outer bands being in overlying relation to said vizor.
4. The structure of claim 1 and in which said side and rear portions comprise at least two thicknesses of material, said earflap being secured to said innermost thickness of material.
References Cited UNITED STATES PATENTS 948,273 2/1910 Finestone et a1. 2-172 1,379,142 5/1921 Wallace 2172 1,445,981 2/ 1923 Strauss 2-172 1,462,279 7/ 1923 Guinzburg 2198 X 2,869,134 1/ 1959 Milstein 2-172 2,878,479 3/1959 Schuessler 2172 3,035,273 5/ 1962 Krystal 2-172 3,076,972 2/ 1963 Prophet et al. 2-l74 3,134,983 6/1964 Lipkin 2-172 3,188,654 6/1965 Rafowitz et a1 2l72 JORDAN FRANKLIN, Primary Examiner.
G. KRIZMANICH, Assistant Examiner.