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 that is rigid, said outer shell being adapted to cover only a user's forehead and the sides of the user's head, wherein the outer shell is configured so that it will not extend over any portion of the top of the user's head; wherein a frontal region of the outer shell has a top edge and a bottom edge that are adapted to be located adjacent the user's forehead;   an impact absorbent inner liner having an exterior surface abutting an inner surface of the outer shell; said inner liner further having an interior surface adapted to conform to the user's forehead and to the sides of the user's head; wherein the inner liner directly contacts the user's forehead and the sides of the user's head from a top edge of the inner liner through to a bottom edge of the inner liner; and   a flexible band that extends between a first end and a second end of the outer shell; and wherein the band and shell are adapted to encircle a user's head and to be secured therearound.   
     
     
         2 . The insert as defined in  claim 1 , wherein each of the outer shell and liner are U-shaped when viewed from the top. 
     
     
         3 . The insert as defined in  claim 1 , wherein the band is adjustable in length; and adjustment of the length of the band changes a circumferential diameter of the insert. 
     
     
         4 . The insert as defined in  claim 1 , wherein the inner liner comprises a layer of padding comprised of a high density foam. 
     
     
         5 . The insert as defined in  claim 4 , wherein the padding of the inner liner extends upwardly to at least a top edge of the outer shell. 
     
     
         6 . The insert as defined in  claim 4 , wherein the padding is continuous along the entire inner surface of the outer shell and the padding is free of apertures. 
     
     
         7 . The insert as defined in  claim 4  wherein the padding is either adhesively secured to the outer shell or is injection molded around the outer shell. 
     
     
         8 . The insert as defined in  claim 1 , wherein the outer shell is fabricated from polycarbonate and the inner liner is fabricated from a visco-elastic material. 
     
     
         9 . The insert as defined in  claim 1 , further comprising at least one engagement member provided on an exterior surface of the outer shell, said engagement member being adapted to engage an inner surface of an outer wall of the cap. 
     
     
         10 . The insert as defined in  claim 9 , wherein the at least one engagement member is one or more pin members that project outwardly from the exterior surface of the outer shell. 
     
     
         11 . The insert as defined in  claim 1 , wherein an upper portion of the insert is of a smaller diameter than a lower portion of the insert. 
     
     
         12 . The insert as defined in  claim 1 , wherein the entire inner liner from a top edge thereof to a bottom edge thereof is in direct abutting contact with the user's head and there are no regions of the inner liner that are spaced a distance away from the user's head. 
     
     
         13 . A cap assembly for protecting a user's head; said assembly comprising:
 a cap including an outer wall that is hemispherical and has a bottom edge; wherein said outer wall includes a front region, a back region; a top region and opposed side regions that bound and define an interior space into which a user's head is received when the cap is worn; wherein the front region is adapted to be located in front of the user's forehead when the cap is worn on the user's head; wherein the back region is adapted to be located behind a back of the user's head; the side regions are adapted to be located next to the sides of the user's head; and the top region is adapted to be located above a top of the user's head; and   a protective insert that is independent of the cap and is selectively engageable around the user's head prior to positioning the cap thereover; wherein the protective insert is adapted to be in direct abutting contact with the user's head; wherein the user's head and the engaged protective insert are receivable within the space defined by the cap; and wherein the protective insert comprises:
 an outer shell that is rigid and U-shaped, said outer shell being positionable proximate only the front region and the side regions of the outer wall of the cap, wherein the outer shell is configured so that it will not extend over any portion of the top of the user's head; wherein at least a portion of the outer shell is spaced a distance away from an interior surface of the cap's front wall; and wherein the outer shell does not extend upwardly to a position adjacent the top region of the cap's outer wall; 
 an impact absorbent inner liner complementary in shape to an inner surface of the outer shell said inner liner being adapted to be placed in abutting contact with the user's head; and 
 a band extending from a first end of the outer shell to a second end of the outer shell; said band being adapted to contact the back of the user's head when the protective insert is engaged on the user's head; wherein the band independently secures the protective insert around the user's head. 
   
     
     
         14 . The cap assembly as defined in  claim 13 , wherein the inner liner has an interior surface and an exterior surface; and the exterior surface is located adjacent the inner surface of the outer shell; and wherein the interior surface of the inner liner is adapted to rest on the user's forehead and sides of the user's head when the protective insert is independently secured around the user's head. 
     
     
         15 . The cap assembly as defined in  claim 13 , wherein the outer shell has an upper end and a lower end and both of the upper and lower end are located adjacent the front region of the cap's outer wall. 
     
     
         16 . The cap assembly as defined in  claim 13 , wherein the inner liner has an upper end and a lower end and both of the upper end and the lower end of the inner liner are located adjacent the front region of the cap's outer wall. 
     
     
         17 . The cap assembly as defined in  claim 16 , wherein the lower end of the inner liner is located flush with or inwardly with respect to the bottom edge of the cap. 
     
     
         18 . The cap assembly as defined in  claim 13 , wherein the cap's outer wall is made from a fabric, the outer shell of the protective insert is fabricated from a rigid material and the inner liner of the insert is fabricated from an impact absorbing material. 
     
     
         19 . A method of protecting a user's head from impact comprising steps of:
 providing a protective insert and a cap, wherein the protective insert is independent of the cap and is positionable on a user's head independently of the cap and prior to placement of the cap on the user's head; wherein the protective insert comprises a rigid outer shell having an impact absorbing inner liner provided on an inner surface of the outer shell, and wherein the protective insert is configured so that it will not extend over any portion of the top of the user's head;   placing the inner liner against the user's forehead and sides of the user's head and so that an upper end of the inner liner and a lower end of the inner liner are both located on the user's forehead and wherein the inner liner and the outer shell do not extend over any portion of the top of the user's head;   placing a band secured to the outer shell around a back of the user's head;   adjusting a length of the band to hold the inner liner tightly against the user's forehead;   conforming the inner liner to a shape of the user's forehead so that the inner liner from a top edge thereof to a bottom edge thereof and the inner liner between the top edge and the bottom edge are in direct contact with the user's forehead;   placing a cap over the user's head; and   placing the cap over the protective insert that has been previously engaged around the user's head.   
     
     
         20 . The method as defined in  claim 19 , further comprising:
 contacting the insert only with a bottom edge region of the cap.   
     
     
         21 . The method as defined in  claim 19 , wherein the placing of the cap over the user's head further includes covering a portion of the user's head that is not located under the protective insert; and wherein the portion of the user's head includes a top region of the user's head that is situated a distance above and rearwardly of the user's forehead. 
     
     
         22 . The method as defined in  claim 19 , further comprising:
 frictionally engaging a lower exterior region of a frontal region of the outer shell with an interior surface of a bottom edge region of the cap.   
     
     
         23 . The insert as defined in  claim 1 , further comprising a first projection provided on one or both of the outer shell and the liner, wherein the first projection extends downwardly for a distance below the bottom edge of the shell; and wherein the first projection is positioned on the one or both of the outer shell and the liner so as to be adapted to cover one of the user's temples. 
     
     
         24 . The insert as defined in  claim 23 , wherein the one or both of the outer shell and the liner further comprises a second projection that is opposed to the first projection; and the second projection extends downwardly for a distance below the bottom edge of the shell; and wherein the second projection is positioned on the one or both of the outer shell and the liner so as to be adapted to cover the other of the user's temples. 
     
     
         25 . The cap assembly as defined in  claim 13 , further comprising a first projection provided on one or both of the outer shell and the liner, wherein the first projection extends downwardly for a distance below the bottom edge of the cap; and wherein the first projection is positioned on the one or both of the outer shell and the liner so as to be adapted to cover one of the user's temples. 
     
     
         26 . The cap assembly as defined in  claim 25 , wherein the one or both of the outer shell and the liner further comprises a second projection that is opposed to the first projection; and the second projection extends downwardly for a distance below the bottom edge of the cap; and wherein the second projection is positioned on the one or both of the outer shell and the liner so as to be adapted to cover the other of the user's temples. 
     
     
         27 . The method as defined in  claim 19 , further comprising:
 extending a first projection downwardly from one or both of the outer shell and beyond a bottom edge of the cap; and   positioning the first projection in a location where the first projection will protect one of the user's temples.   
     
     
         28 . The method as defined in  claim 27 , further comprising:
 extending a second projection downwardly from one or both of the outer shell and beyond the bottom edge of the cap in a position opposed to the first projection; and   positioning the second projection in a location where the second projection will protect the other of the user's temples.