Protective ball cap

Abstract

A protective insert for a ball cap and a cap incorporating the same. The insert includes a rigid shell and a complementary impact-absorbent liner that covers and protects only the forehead and portions of the sides of the user's head. Bottom edges of the shell, liner and cap are generally aligned along the same horizontal plane. Alternatively, the shell and liner terminate a distance inwardly from the bottom edge of the cap. An adjustable band is secured to the ends of the shell and the band and shell encircle the circumference of the user's head. One or more engagement members may 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 top edge 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;
 an outer shell adapted to be received within a space defined by an inner surface of an outer wall of the cap; said shell being adapted to cover only the user's forehead and sides of their head; and   an inner liner complementary in shape to the outer shell; wherein the liner is positioned adjacent an inner surface of the shell and is adapted to be disposed adjacent the user's head.   
     
     
         2 . The protective insert as defined in  claim 1 , wherein the outer shell is substantially rigid. 
     
     
         3 . The protective insert as defined in  claim 1 , wherein the inner liner is fabricated from a shock absorbent material. 
     
     
         4 . The protective insert as defined in  claim 1 , wherein the shell has a top edge and a bottom edge and the liner has a top edge and a bottom edge; and the bottom edges of the shell and the liner are substantially aligned along a same plane. 
     
     
         5 . The protective insert as defined in  claim 4 , wherein the bottom edge of the shell and the bottom edge of the liner are disposed in the same plane. 
     
     
         6 . The protective insert as defined in  claim 1 , wherein the outer shell has a first side edge and a second side edge, and the insert further comprises a band which extends between the first and second side edges. 
     
     
         7 . The protective insert as defined in  claim 6 , wherein the band and the outer shell together form a closed loop and the band and the outer shell together are adapted to encircle a wearer's head. 
     
     
         8 . The protective insert as defined in  claim 7 , wherein the closed loop formed by the outer shell and band have a circumference, and wherein the circumference of this closed loop decreases in size from proximate a bottom edge of the shell to proximate a top edge thereof. 
     
     
         9 . The protective insert as defined in  claim 1 , wherein the insert has a front region adapted to be positioned adjacent a user's forehead, and wherein the front region is curved from a bottom edge to a top edge thereof, and wherein the curvature of the front region is adapted to mirror a curvature of a user's forehead. 
     
     
         10 . The protective insert as defined in  claim 6 , wherein the band is selectively adjustable in length, and wherein adjustment of the length of the band changes a circumferential diameter of the insert. 
     
     
         11 . The insert as defined in  claim 1 , wherein each of the shell and the liner are generally U-shaped when viewed from above. 
     
     
         12 . The insert as defined in  claim 1 , wherein the shell includes a central region, a first side region and a second side region, wherein the first and second side regions extend outwardly in opposite directions from the central region; and wherein a first portion of the top edge of the shell extends along a top end of the central region, a second portion of the shell's top edge edges along a top end of the first side region; and a third portion of the shell's top edge extends along the second side region; and wherein the first portion of the top edge is disposed in a different plane to the second and third portions of the top edge. 
     
     
         13 . The protective insert as defined in  claim 12 , further comprising a first angled section extending between the first portion of the top edge and the second portion of the top edge; and a second angle section extending between the first portion of the top edge and the third portion of the top edge. 
     
     
         14 . The insert as defined in  claim 12 , wherein the central region is of a first height measured between the first portion of the shell's top edge and the bottom edge of the shell; and each of the first and second sides is of a second height as measured from the second portion of the shell's top edge or the third portion thereof to the bottom edge of the shell; and the first height is greater than the second height. 
     
     
         15 . The protective 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 opposing sides of the central region; wherein each of the side regions is adapted to be disposed adjacent one of the sides of the user's head, and wherein the padding has a thickness as measured from an exterior surface adjacent the shell and an interior surface adapted to be located adjacent the user's head; and wherein the central region of padding is thicker than the side regions of padding. 
     
     
         16 . A cap assembly for protecting a user's head; said assembly comprising:
 a cap including a substantially hemispherical outer wall having an inner surface and a bottom edge; a space defined by the inner surface of the outer wall; and   a protective insert receivable within the space; wherein said insert comprises:
 an outer shell adapted to cover only the user's forehead and sides of their head; 
 an inner liner complementary in shape to an interior surface of the outer shell; wherein the liner is adapted to be disposed adjacent the user's forehead and the sides of the user's head; wherein each of the shell and liner has a bottom edge and wherein the bottom edges of the liner and the shell do not extend beyond the bottom edge of the cap. 
   
     
     
         17 . The projective cap assembly as defined in  claim 16 , 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 an impact absorbing material. 
     
     
         18 . The protective cap assembly as defined in  claim 16 , further comprising a band connecting a first side of the shell to a second side of the shell, and wherein the band and shell together form a closed loop and are adapted to encircle the circumference of the user's head. 
     
     
         19 . The protective cap assembly as defined in  claim 18 , wherein the closed loop formed by the outer shell and band have a circumference, and wherein the circumference of this closed loop decreases in size from proximate a bottom edge of the shell to proximate a top edge thereof. 
     
     
         20 . The protective cap assembly as defined in  claim 18 , wherein the insert is free of any bands or components which will pass over a top region of the user's head. 
     
     
         21 . The protective cap assembly as defined in  claim 16 , wherein the protective insert is independent of and separate from the cap.