Form-retaining insert for caps

Claim 2

A form-maintaining insert for a cap which comprises a generally flat sheet of form-retaining material that has a front portion which is generally similar to the front portion of the crown of said cap and which is insertable within the front portion of said cap to underlie and to confront said front portion of said crown in face-to-face relation and that has a rear portion which is generally similar to the rear portion of said crown of said cap and which is insertable within the rear portion of said cap to underlie and to confront said rear portion of said crown in face-to-face relation, said front portion of said sheet having a curved periphery, said rear portion of said sheet having a periphery which is, at least in part, curved, said sheet having a severance line therein which extends forwardly from the rear edge of said rear portion into said front portion to define left and right areas for said rear portion which have confronting edges, said left and right areas being bowable to enable the confronting edge on one of said areas to lap over the confronting edge of the other of said areas with a consequent reduction in the effective width of said rear portion of said insert, said insert resisting the bowing of said left and right areas of said rear portion thereof and developing restorative forces which cause said left and right areas of said rear portion to apply outwardly-directed forces to said cap, adjacent the sides of said crown, that will develop tensile forces in said crown which will resist wrinkling or creasing of said crown, said periphery of said rear portion of said sheet providing a fold-line about which the rear wall of said cap can be folded inwardly and adjacent a confronting surface of said sheet to reduce the space occupied by said cap to a desired value.

Claim 3

A form-maintaining insert as claimed in claim 1 wherein the maximum width of said rear portion of said insert is greater than the maximum width of said crown of said cap whenever said confronting edges defined by said severance line are in confronting, abutting engagement with each other.

Claim 4

A form-maintaining insert as claimed in claim 1 wherein the side edges of said rear portion of said insert engage the upper portions of the side walls of said cap whenever said insert is positioned within said cap in face-to-face relation with the inner surface of said crown of said cap.

Claim 5

A form-maintaining insert as claimed in claim 1 wherein the maximum width of said rear portion of said insert is greater than the maximum width of said crown of said cap whenever said confronting edges defined by said severance line are in confronting, abutting engagement with each other, and wherein the side edges of said rear portion of said insert engage the upper portions of the side walls of said cap whenever said insert is positioned within said cap in face-to-face relation with the inner surface of said crown of said cap.

Claim 6

A form-maintaining insert as claimed in claim 1 wherein the rear edge of said insert engages the upper portion of said rear wall of said cap whenever said insert is positioned within said cap in face-to-face relation with the inner surface of said crown of said cap.

Claim 7

A form-maintaining insert as claimed in claim 1 wherein the maximum width of said rear portion of said insert is greater than the maximum width of said crown of said cap whenever said confronting edges defined by said severance line are in confronting, abutting engagement with each other, and wherein the side edges of said rear portion of said insert engage the upper portions of the side walls of said cap and the rear edge of said insert engages the upper portion of said rear wall of said cap whenever said insert is positioned within said cap in face-to-face relation with the inner surface of said crown of said cap.

Claim 8

A form-maintaining insert as claimed in claim 1 wherein additional severance lines extend forwardly from said rear edge of said rear portion of said insert, and wherein said additional severance lines define edges which can be lapped to permit said rear portion of said insert to be bent.

Claim 9

A form-maintaining insert as claimed in claim 1 wherein additional severance lines extend forwardly from said rear edge of said rear portion of said insert, and wherein said additional severance lines define edges which can be lapped to permit said rear portion of said insert to be bent, said additional severance lines normally holding the edges defined thereby against lapping but responding to cutting forces to free said edges for lapping movement.

Claim 10

A form-maintaining insert as claimed in claim 1 wherein additional severance lines extend forwardly from said rear edge of said rear portion of said insert, wherein said additional severance lines define edges which can be lapped to permit said rear portion of said insert to be bent, and wherein the first said and said additional severance lines can coact to permit said insert to be bent to have a generally spherical configuration that is similar to the generally spherical configuration which said crown will have when said cap is being worn.

Claim 11

A form-maintaining insert as claimed in claim 1 wherein additional severance lines extend forwardly from said rear edge of said rear portion of said insert, wherein said additional severance lines define edges which can be lapped to permit said rear portion of said insert to be bent, wherein the first said and said additional severance lines can coact to permit said insert to be bent to have a generally spherical configuration that is similar to the generally spherical configuration which said crown will have when said cap is being worn, and wherein said insert can continue to maintain wrinkle-resisting and crease-resisting tensile forces within said crown after said insert has been bent to have said generally spherical configuration.

Claim 12

A form-maintaining insert as claimed in claim 1 wherein said sheet is wider than it is long whenever it is in a unstressed state.

Claim 13

A form-maintaining insert for a cap which comprises a generally flat sheet of form-retaining material that has a front portion which is generally similar to the front portion of the crown of said cap and which is insertable within the front portion of said cap to underlie and to confront said front portion of said crown in face-to-face relation and that has a rear portion which is generally similar to the rear portion of said crown of said cap and which is insertable within the rear portion of said cap to underlie and to confront said rear portion of said crown in face-to-face relation, said front portion of said insert having a curved periphery, said rear portion of said insert having a periphery which is, at least in part, curved, said insert having a severance line therein which extends forwardly from the rear edge of said rear portion a substantial distance toward said front portion to define left and right areas for said rear portion, said severance line defining an open space which is spaced rearwardly of the forward-most point on said curved periphery of said front portion and which is spaced a substantial distance forwardly of the rearward-most point on said periphery of said rear portion to dispose said open space in registry with at least a part of the central portion of said crown of said cap, said left and right areas for said rear portion having edges that are intermediate said open space and said periphery of said rear portion and that confront each other, said left and right areas being movable relative to each other to enable the confronting edge on one of said areas to lap over the confronting edge of the other of said areas with a consequent reduction in the effective width of said rear portion of said insert, said insert resisting the relative movement of said left and right areas of said rear portion thereof and developing restorative forces which cause said left and right areas of said rear portion thereof to apply outwardly-directed forces to said cap, adjacent the sides of said crown, that will develop tensile forces in said crown which will resist wrinkling or creasing of said crown, said periphery of said rear portion of said insert providing a fold-line about which the rear wall of said cap can be folded inwardly and adjacent a confronting surface of said insert to reduce the space occupied by said cap to a desired value.

Claim 14

A form-maintaining insert for a cap which comprises a generally flat sheet of form-retaining material that has a front portion which is generally similar to the front portion of the crown of said cap and which is insertable within the front portion of said cap to underlie and to confront said front portion of said crown in face-to-face relation and that has a rear portion which is generally similar to the rear portion of said crown of said cap and which is insertable within the rear portion of said cap to underlie and to confront said rear portion of said crown in face-to-face relation, said front portion of said insert having a curved periphery, said rear portion of said insert having a periphery which is, at least in part, curved, said insert having a severance line therein which extends forwardly from the rear edge of said rear portion a substantial distance toward said front portion to define left and right areas for said rear portion, said severance line defining an open space which is spaced rearwardly of the forward-most point on said curved periphery of said front portion and which is spaced a substantial distance forwardly of the rearward-most point on said periphery of said rear portion to dispose said open space in registry with at least a part of the central portion of said crown of said cap, said left and right areas for said rear portion having edges that are intermediate said open space and said periphery of said rear portion and that confront each other, said left and right areas being movable relative to each other to enable the confronting edge on one of said areas to lap over the confronting edge of the other of said areas with a consequent reduction in the effective width of said rear portion of said insert, said insert resisting the relative movement of said left and right areas of said rear portion thereof and developing restorative forces which cause said left and right areas of said rear portion thereof to apply outwardly-directed forces to said cap, adjacent the sides of said crown, that will develop tensile forces in said crown which will resist wrinkling or creasing of said crown, said periphery of said rear portion of said insert providing a fold-line about which the rear wall of said cap can be folded inwardly and adjacent a confronting surface of said insert to reduce the space occupied by said cap to a desired value.

Claim 15

A form-maintaining insert as claimed in claim 12 wherein the maxiumum width of said rear portion of said insert is greater than the maximum width of said crown of said cap whenever said intermediate, confronting edges defined by said severance line are in confronting, abutting engagement with each other.

Claim 16

A form-maintaining insert as claimed in claim 12 wherein the maxiumum width of said rear portion of said insert is greater than the maximum width of said crown of said cap whenever said intermediate, confronting edges defined by said severance line are in confronting, abutting engagement with each other, and wherein the side edges of said rear portion of said insert engage the upper portions of the side walls of said cap whenever said insert is positioned within said cap in face-to-face relation with the inner surface of said crown of said cap.

Claim 17

A form-maintaining insert as claimed in claim 12 wherein the maxiumum width of said rear portion of said insert is greater than the maximum width of said crown of said cap whenever said intermediate, confronting edges defined by said severance line are in confronting, abutting engagement with each other, and wherein the side edges of said rear portion of said insert engage the upper portions of the side walls of said cap and the rear edge of said insert engages the upper portion of said rear wall of said cap whenever said insert is positioned within said cap in face-to-face relation with the inner surface of said crown of said cap.

Claim 18

A form-maintaining insert as claimed in claim 12 wherein additional severance lines extend forwardly from said rear edge of said rear portion of said insert but do not extend to said open space, and wherein said additional severance lines define edges which can be lapped adjacent said rear edge of said rear portion to permit said rear portion of said insert to be bent, said additional severance lines normally holding the edges defined thereby against lapping but responding to cutting forces to free said edges for lapping movement.

Claim 19

A form-maintaining insert as claimed in claim 12 wherein said insert is dimensioned so it can be generally flat whenever it is disposed within said cap in face-to-face engagement with said inner surface of said crown of said cap.

Claim 20

A form-maintaining insert as claimed in claim 12 wherein the front of said open space is closer to the front edge of said front portion of said insert than the rear of said open space is to the rear edge of said rear portion of said insert.

Claim 21

A form-maintaining insert as claimed in claim 12 wherein said severance line and said open space define edges that are moveable relative to each other in a direction normal to said insert and that extend forwardly into positions intermediate the front edge of said crown of said cap and the middle of said crown of said cap.

Claim 22

A form-maintaining insert as claimed in claim 12 wherein said insert is wider than it is long whenever it is in an unstressed state.