Braided Article of Headgear and Method of Making

Abstract

A braided article of headgear and a hat form are disclosed. In one embodiment, the hat form has a double crown portion and a double bill portion. The braided article comprises a braided construction with at least one strand that extends continuously from a right portion of the crown to a left portion of the crown. The braided article may include a single layer or a double layer construction comprising an inner braid layer and an outer braid layer.

What is claimed is: 
     
         1 . An article of headgear having a crown; the crown having coronal plane, a transverse plane and a sagittal plane, the article of headgear comprising:
 the crown with an interior void sized and configured to receive a wearer's head;   the crown comprising a front portion disposed generally forward of the coronal plane and a rear portion disposed opposite the front portion, the rear portion disposed generally rearward of the coronal plane;   the crown comprising a left side portion disposed on one side of the sagittal plane, and a right side portion disposed opposite the left side portion, on the other side of the sagittal plane;   the crown comprising a braided construction with at least one strand;   the strand extending continuously from the left side portion to the right side portion.   
     
     
         2 . The article of headgear according to  claim 1 , wherein the crown includes a band disposed proximate an opening to the interior void;
 wherein the left side portion includes a left base portion disposed proximate the band;   wherein the right side portion includes a right base portion disposed proximate the band; and   wherein the strand extends continuously from the left base portion to the right base portion.   
     
     
         3 . The article of headgear according to  claim 1 , further comprising a bill attached to the crown. 
     
     
         4 . The article of headgear according to  claim 3 , wherein the strand extends continuously from the bill to the left side portion. 
     
     
         5 . The article of headgear according to  claim 3 , wherein the strand extends continuously from an under peak portion of the bill to an over peak portion of the bill. 
     
     
         6 . The article of headgear according to  claim 1 , further comprising a second strand;
 wherein the second strand is spaced from the strand;   the second strand extending continuously from the left side portion to the right side portion; and   wherein the second strand is shorter than the strand.   
     
     
         7 . The article of headgear according to  claim 6 , further comprising a bill attached to the crown; and wherein the second strand extends continuously from the bill to the left side portion. 
     
     
         8 . A hat form used to create an article of headgear, the hat form comprising:
 a first side and a second side opposite the first side, wherein the first side is integrally formed with the second side;   the first side including a first crown portion;   the second side including a second crown portion;   wherein the first crown portion generally aligns with the second crown portion, thereby forming a double hat form; and   wherein the hat form is configured to be fed into a braid machine and receive an overbraided matrix of strands on its outer surface.   
     
     
         9 . The hat form according to  claim 8 , wherein the first side includes a first bill portion connected to the first crown portion. 
     
     
         10 . The hat form according to  claim 9 , wherein the second side includes a second bill portion connected to the second crown portion. 
     
     
         11 . The hat form according to  claim 10 , wherein the first bill portion generally aligns with the second bill portion. 
     
     
         12 . The hat form according to  claim 9 , wherein the first bill portion includes a first underbill portion extending from the first bill portion. 
     
     
         13 . The hat form according to  claim 10 , wherein the second bill portion includes a second underbill portion extending from the second bill portion. 
     
     
         14 . An article of headgear having a crown; the crown having coronal plane, a transverse plane and a sagittal plane, the article of headgear comprising:
 the crown with an interior void sized and configured to receive a wearer's head;   the crown comprising a front portion disposed generally forward of the coronal plane and a rear portion disposed opposite the front portion, the rear portion disposed generally rearward of the coronal plane;   the crown comprising a left side portion disposed on one side of the sagittal plane, and a right side portion disposed opposite the left side portion, on the other side of the sagittal plane;   the crown comprising an inner braid layer and an outer braid layer.   
     
     
         15 . The article of headgear according to  claim 14 , wherein the inner braid layer includes a strand strand extending continuously from the left side portion to the right side portion. 
     
     
         16 . The article of headgear according to  claim 14 , wherein the outer braid layer includes a strand strand extending continuously from the left side portion to the right side portion. 
     
     
         17 . The article of headgear according to  claim 14 , wherein the article of headgear includes a reinforcing member disposed between the inner braid layer and the outer braid layer. 
     
     
         18 . The article of headgear according to  claim 14 , wherein the inner braid layer includes at least one strand and wherein the at least one strand extends continuously from the inner braid layer to the outer braid layer. 
     
     
         19 . The article of headgear according to  claim 14 , further comprising a bill attached to the crown. 
     
     
         20 . The article of headgear according to  claim 19 , wherein the inner braid layer and the outer braid layer extend through the bill.