Protective ball cap

Abstract

A protective insert for a ball cap and a cap incorporating the same. The insert includes a rigid, U-shaped outer shell and a complementary impact absorbent liner. The insert covers and protects only the forehead, temples and portions of the sides of the user's head. The shell and liner have bottom edges disposed inwardly relative to a bottom edge of the cap. Projections provided on the shell and liner extend downwardly beyond the cap's bottom edge and cover the user's temples. Adjustable bands and straps secured to the shell retain the insert on the user's head. One or more engagement members secure the insert to the cap. The material of the liner is thicker in a front central region and thinner toward the side regions of the insert. The liner material extends beyond the peripheral edges of the shell so that the shell does not directly contact the user's head.

1 . A protective insert for a cap to be worn on a user's head, said insert comprising:
 a substantially rigid outer shell adapted to be received within a space defined by an inner surface of an outer wall of the cap and adapted to cover only the user's forehead and sides of their head;   an impact absorbent inner liner complementary in shape to the outer shell; wherein the liner is received inside a space defined by an inner surface of the shell and is adapted to be disposed adjacent the user's head; wherein each of the shell and liner has a bottom edge and includes a first projection which extends downwardly beyond the bottom edge thereof; and the first projection is adapted to extend at least partially over one of the user's temples; and wherein the shell and liner are adapted to be substantially disposed above a bottom edge of the cap and the first projection extends downwardly beyond the bottom edge of the cap.   
     
     
         2 . The insert as defined in  claim 1 , wherein each of the shell and liner includes a second projection which is opposed to the first projection and extends downwardly beyond the bottom edge thereof; and the second projection is adapted to extend downwardly beyond the bottom edge of the cap and at least partially cover the other of the user's temples. 
     
     
         3 . The insert as defined in  claim 1 , wherein each of the shell and liner are generally U-shaped when viewed from the top. 
     
     
         4 . The insert as defined in  claim 1 , wherein the shell comprises a central region adapted to cover the user's forehead, and a pair of side regions each of which extends outwardly from the central region and is adapted to cover the sides of the user's head; and wherein the insert further comprises a flexible band secured to each of the side regions; and wherein the band and shell together are adapted to fit circumferentially around the user's head in a horizontal orientation. 
     
     
         5 . The insert as defined in  claim 4 , wherein the band is adjustable in length; and adjustment of the length of the band changes a circumferential diameter of the insert. 
     
     
         6 . The insert as defined in  claim 1 , wherein the liner comprises a layer of padding including a central region adapted to be disposed adjacent the user's forehead; and two opposed side regions each extending outwardly from one side of central region of padding and adapted to be disposed adjacent one of the sides of the user's head, and wherein the padding has a thickness and the thickness thereof varies along the liner. 
     
     
         7 . The insert as defined in  claim 6 , wherein the padding in the central region of the liner is thicker than the padding in the side regions of the liner. 
     
     
         8 . The insert as defined in  claim 6 , wherein the padding of the liner extends outwardly beyond both of an upper edge and the bottom edge of the shell. 
     
     
         9 . The insert as defined in  claim 6 , wherein the padding is substantially continuous along the entire inner surface of the shell and the padding is substantially free of apertures. 
     
     
         10 . The insert as defined in  claim 6  wherein the padding is either adhesively secured to the shell or is injection molded around the shell. 
     
     
         11 . The insert as defined in  claim 1 , wherein the shell is fabricated from polycarbonate and the liner is fabricated from a visco-elastic material. 
     
     
         12 . The insert as defined in  claim 1 , further comprising at least one engagement member provided on an exterior surface of the shell, said engagement member being adapted to engage the inner surface of the outer wall of the cap. 
     
     
         13 . The insert as defined in  claim 12 , wherein the at least one engagement member comprises one or more of a pin member, a detent, or a hook and loop fastener. 
     
     
         14 . The insert as defined in  claim 1 , further comprising a first strap provided on the shell wherein the strap extends from proximate a first terminal region of the shell to a second terminal region of the shell, and the first strap is generally semi-circular in shape and is adapted to pass over the crown of the user's head. 
     
     
         15 . The insert as defined in  claim 14 , further comprising a second strap which extends from a top end of a central region of the shell and terminates in the first strap; and wherein the second strap is adapted to extend from a top end of the user's forehead to the crown of their head. 
     
     
         16 . The insert as defined in  claim 14 , wherein one or both of the first and second straps are adjustable in length. 
     
     
         17 . The insert as defined in  claim 15 , further comprising two apertures defined in the shell, and wherein the free ends of the first strap is threaded through one of the apertures; and wherein apart from these two apertures, the shell is free of other openings. 
     
     
         18 . The insert as defined in  claim 2 , wherein the bottom edge of the shell is disposed generally along a plane with the exception of the two projections which extend outwardly for a distance beyond the plane. 
     
     
         19 . A cap assembly for protecting a users head; said assembly comprising:
 a cap including a substantially hemispherical outer wall having a bottom edge;   a space defined by the outer wall; and   a protective insert receivable within the space; wherein said insert comprises:
 a substantially rigid U-shaped outer shell adapted to cover only the user's forehead and sides of their head; 
 an impact absorbent inner liner complementary in shape to the outer shell; wherein the liner is received inside a space defined by an inner surface of the shell; wherein the liner is adapted to be disposed adjacent the user's head; wherein each of the shell and liner has a bottom edge disposed upwardly relative from the bottom edge of the cap; and at least one of the shell and liner includes a first projection which extends downwardly beyond the bottom edge thereof and beyond the bottom edge of the cap; and wherein the first projection is adapted to extend at least partially over one of the user's temples. 
   
     
     
         20 . The projective cap assembly as defined  claim 19 , wherein each of the shell and liner includes a first projection and a second projection which is opposed to the first projection; and both of the first and second projections extend downwardly beyond the bottom edge of the shell and liner and beyond the bottom edge of the cap; and each of the first and second projections is adapted to at least partially cover and protect one of the user's temples. 
     
     
         21 . The protective cap assembly as defined in  claim 19 , further comprising:
 a peak extending outwardly away from a front region of the outer wall of the cap; and   a detent extending outwardly from a front surface of the insert; and   
       wherein the detent engages a lower surface of the peak. 
     
     
         22 . The protective cap assembly as defined in  claim 20 , wherein the first and second projections are generally V-shaped. 
     
     
         23 . The projective cap assembly as defined in  claim 19 , wherein the cap's outer wall is made from a fabric, the shell of the insert is fabricated from a rigid material and the liner of the insert is fabricated from a impact absorbing material.