Molded baseball cap

Abstract

A headwear article includes a crown portion sized to cover a portion of a wearer's forehead when the wearer wears the headwear article and a visor extending laterally from the crown. The crown and the visor are formed from a single, one-piece molded body that includes an upper fabric layer, a lower fabric layer facing the wearer's head, and an intermediate layer disposed between the upper fabric layer and the lower fabric layer, and each of the upper fabric layer, the lower fabric layer, and the intermediate layer extend continuously between the crown and the visor. A transition angle is defined at a transition between the visor and the crown, where the transition angle is obtuse.

Description

Cross-reference to related applications

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 559,244, filed February 29, 2024, the entire disclosure of which is incorporated herein by reference. Technical Field

[0002] The present invention relates to a headwear, for example, a hat having a crown portion and a visor. Background Technology

[0003] Headwear, including the crown and visor, such as sun hats with a partial crown or caps with a full crown and visor (e.g., baseball caps), is typically used for leisure, recreation, and / or sporting activities to provide comfort against environmental factors (e.g., sun, wind, rain, etc.) and to protect the wearer's eyes from sunlight during use. Standard headwear usually has multiple seams to connect components such as the visor and sweatband to the crown or cap, where the cap is formed by panels also connected by multiple seams. These seams create numerous hard edges that rest against the wearer's head and can cause discomfort when worn.

[0004] Traditional sun visors or baseball-style caps consist of a hemispherical crown portion to fit the wearer's head, and a visor or brim portion attached to the front of the hemispherical crown portion. Several basically triangular pieces called visors are sewn together to form the crown. Typically, a baseball cap has six visors, which are sewn together to form the round shape of the crown. The visor is made of cardboard or plastic and is attached to the front portion of the lower perimeter edge.

[0005] Furthermore, the visor or brim of a hat typically connects to the hat at a sharp right angle and may include multiple folds as a connection, creating a more rigid edge that contacts the wearer's forehead during wear. Additionally, forehead shapes can vary from narrow to wide, resulting in varying pressure points along the front and / or center of the wearer's forehead when wearing a hat with a visor, as hats are often shaped to fit a standard configuration for various head shapes. These pressure points can cause marks along the forehead and fatigue for the wearer.

[0006] The goal is to provide a headwear with a visor that is comfortable to wear and minimizes pressure points along the wearer's forehead regardless of forehead shape (from narrow to wide). Summary of the Invention

[0007] A headwear item includes a one-piece molded structure. In an example embodiment, a single one-piece molded body is formed from a textile material package including an outer or upper fabric layer, an inner or lower fabric layer, and an intermediate foam layer of one or more selected stiffeners disposed between the upper and lower fabric layers. Additional functional layers may be incorporated into the package. The package is formed via a one-step molding process utilizing heat and pressure to create the one-piece molded body or structure. In a specific embodiment, the headwear item may be a baseball cap including a closed crown and visor, or a tennis sun cap including an open crown and visor.

[0008] The above and further features and advantages of the present invention will become clear upon consideration of the following detailed description of specific embodiments. Attached Figure Description

[0009] Figure 1A This is a side view of a one-piece or one-piece headwear item in the form of a hat, according to an embodiment described herein.

[0010] Figure 1B yes Figure 1A Front view of the hat.

[0011] Figure 1C yes Figure 1A The rear view of the hat.

[0012] Figure 2A yes Figure 1A A cross-sectional side view of the hat.

[0013] Figure 2B yes Figure 1A An enlarged cross-sectional side view of a portion of the hat, including the molded button at the crown portion of the hat.

[0014] Figure 2C yes Figure 1A An enlarged cross-sectional side view of a portion of the hat, including the transition area between the visor and the crown.

[0015] Figure 3A It is used to form Figure 1A The hat is viewed individually on each of its layers.

[0016] Figure 3B yes Figure 1A A view of another embodiment of the reinforcing plate of the hat.

[0017] Figure 3C Is with Figure 1A The depicted hat is a cross-sectional side view of a further embodiment of a hat that is similar to but incorporates a reinforcing plate inside the hat (where the section passes through the hat and is cut at a series of through holes passing through the reinforcing plate of the hat).

[0018] Figure 4A This is a cross-sectional side view of the mold, including first and second shell portions separated from each other, and portions stacked between the shell portions in an aligned orientation for forming. Figure 1A The material layers of the hat.

[0019] Figure 4B yes Figure 4A An enlarged cross-sectional side view of the mold, including the front end sections of the first and second shell portions that form the visor of the hat.

[0020] Figure 4C yes Figure 4A An enlarged cross-sectional side view of the mold, including the middle section of the first and second shell portions forming the crown apex of the hat and the molded button along the crown of the hat.

[0021] Figure 4D yes Figure 4A A cross-sectional side view of the mold, wherein the layers are pressed between the first and second housing portions.

[0022] Figure 4E yes Figure 4A A cross-sectional side view of the mold, wherein... Figure 4D After the molding process shown, the first and second shell parts separate to form Figure 1A The hat.

[0023] Figure 5 It describes the use of forming a single, one-piece headwear item (such as...) Figure 1A A flowchart of an example embodiment of the molding process for a hat.

[0024] Figure 6 yes Figure 1A An enlarged cross-sectional side view of a portion of the hat shows the transition area between the hat's visor and crown, and how the crown bends to accommodate different head sizes.

[0025] Figure 7A A schematic plan view depicting how the visor of a traditional hat adapts to different head sizes and shapes (narrow, standard, and wide).

[0026] Figure 7B Describing as Figure 7A The diagram shows the visor of a traditional hat for different head sizes (top plan view and front elevation view), and how the visor applies a hard edge and / or pressure point along the wearer's forehead in the transition area between the visor and the crown.

[0027] Figure 8A Depicting head-wearing items such as those described in this article (e.g., Figure 1AThe visor of the hat is shown in a schematic plan view of how it is worn by wearers with different head sizes (narrow, standard, and wide).

[0028] Figure 8B Describing as Figure 8A The diagrams shown (top plan and front elevation view) illustrate different head sizes of the visor and how the visor adapts to different head sizes and minimizes or eliminates hard edges / pressure points on the wearer's forehead at the transition area between the visor and the crown, regardless of head size / shape.

[0029] Figure 9 This is a cross-sectional side view of another embodiment of a headwear item in the form of a hat, which is similar to... Figure 1A The hat has an intermediate foam layer of varying thickness.

[0030] Figure 10A This is a side view of another embodiment of a headwear item in the form of a hat, including a one-piece molded component (which includes a first portion of a visor and a crown) and a second molded component that forms the second portion of the crown and is attached to the first portion.

[0031] Figure 10B yes Figure 10A A cross-sectional side view of an item worn on the head.

[0032] Figure 11 It describes the process of molding two parts and then assembling them together to form a headwear item (e.g., Figure 10A A flowchart of an example process (the hat).

[0033] Figure 12A This is a side view of a further embodiment of a headwear item in the form of a sun hat.

[0034] Figure 12B yes Figure 12A A cross-sectional side view of a sun hat.

[0035] Figure 12C yes Figure 12A The lower perspective view of the sun hat shows the interior of the crown portion or the surface facing the forehead, as well as the grooves or channels provided along the surface.

[0036] Figure 13A This is a side view of another embodiment of a headwear item in the form of a hat, including a molded one-piece first part and a second part, the second part comprising a plurality of pieces or components that are combined to form the second part.

[0037] Figure 13B yes Figure 13AA partial, pre-disassembled 3D view of the hat, showing the components of the second part already separated.

[0038] Figure 14 It describes forming a headwear item by molding a first part and then combining the first part with a second part (e.g., Figure 13A The flowchart of an example process for a hat, the second part includes a series of molded parts or sections assembled together.

[0039] The same reference numerals have been used to identify the same elements throughout this disclosure. Detailed Implementation

[0040] In the following detailed description, reference is made to the accompanying drawings, which form a part of this document, wherein like numerals designate like components throughout, and wherein illustrative embodiments that may be practiced are shown. It should be understood that other embodiments may be utilized, and structural or logical changes may be made without departing from the scope of this disclosure. Therefore, the following detailed description should not be considered limiting, and the scope of the embodiments is defined by the appended claims and their equivalents.

[0041] Various aspects of this disclosure are disclosed in the accompanying description. Alternative embodiments and equivalents of this disclosure may be devised without departing from the spirit or scope thereof. It should be noted that any discussion herein with reference to “an embodiment,” “an embodiment,” “an exemplary embodiment,” etc., indicates that the described embodiment may include specific features, structures, or characteristics, and such specific features, structures, or characteristics are not necessarily included in every embodiment. Furthermore, references to the foregoing do not necessarily constitute references to the same embodiment. Finally, whether explicitly described or not, those skilled in the art will readily understand that any specific feature, structure, or characteristic of a given embodiment may be used in combination with those features, structures, or characteristics of any other embodiment discussed herein.

[0042] Various operations can be described as a series of discrete actions or operations performed sequentially, in a manner most conducive to understanding the claimed subject matter. However, the order in which they are described should not be construed as implying that these operations are necessarily sequentially dependent. In particular, these operations may not be performed in the order presented. The described operations may be performed in an order different from that of the described embodiments. Various additional operations may be performed and / or the described operations may be omitted in additional embodiments.

[0043] For the purposes of this disclosure, the phrase "A and / or B" means (A), (B), or (A and B). For the purposes of this disclosure, the phrase "A, B and / or C" means (A), (B), (C), (A and B), (A and C), (B and C), or (A, B and C).

[0044] In the context of embodiments of this disclosure, the terms “comprising,” “including,” “having,” etc., are used synonymously.

[0045] This document describes a one-piece or single-piece headwear comprising a crown portion and a visor, wherein the crown portion and the visor of the headwear are formed as a single, single-piece component or structure. The single-piece headwear can be formed from a material capable of forming the outline of the headwear and any structure located on the internal and / or external surface of the headwear. In embodiments, the material is a thermoformable textile laminate (also referred to herein as a fabric laminate) comprising multiple layers including one or more fabric (textile) layers, one or more foam layers, and optionally one or more structural support layers disposed within the headwear (i.e., between two or more of the multiple layers forming the headwear), wherein the fabric laminate is capable of being compression molded.

[0046] In an example embodiment, the crown portion and the visor include multiple layers (e.g., a first or upper fabric layer, a middle layer, and a second or lower fabric layer), wherein the multiple layers are combined during molding to form a one-piece molded member or structure that defines the entire visor and at least one crown portion that extends from the visor at an obtuse angle and is appropriately sized to cover at least a portion of the forehead of the wearer of the headwear.

[0047] The layers forming the one-piece molded component of the headwear extend continuously from the visor to the transition area surrounding the visor and the crown portion, and then to the crown portion. The crown portion may include the entire crown portion having a dome-shaped component sized to cover the top or apex of the wearer's head (i.e., the top of the wearer's head). Alternatively, the crown portion may be an open crown that only covers a portion of the wearer's head (e.g., not covering the top or apex of the wearer's head), including the front or forehead portion of the wearer's head.

[0048] Some non-limiting exemplary embodiments of headwear described herein include: a single, one-piece hat, wherein the crown portion comprises a complete or full crown that surrounds the wearer's head (example embodiments of which are described herein and in Figures 1A-2C (Depicted in the text); a sun hat, wherein the crown portion is an open crown that partially covers the wearer's head (example embodiments of which are described herein and in the text). Figure 12A and Figure 12B (as depicted herein); a hat comprising two or more molded parts (example embodiments thereof are described herein and in...) Figure 10A and Figure 10B(as depicted herein), wherein the first part includes a one-piece molded component comprising a visor and a first crown portion, and at least one additional portion forming an additional crown portion defining the crown of the hat; and a hat comprising molded components (example embodiments thereof are described herein and in...). Figure 13A and Figure 13B (as depicted in the image), wherein the first part includes a one-piece molded component comprising a visor and a first crown portion, and a second crown portion is formed by one or more molded components that combine with the first crown portion to define the crown portion of the hat.

[0049] In each embodiment, the crown portion of the headwear is integral with the visor and is formed as a single one-piece molded component by multiple layers, wherein at least some layers are planar and molded into the shape forming the single one-piece molded component. This shape defines a transition area between the visor and the crown portion, with an obtuse transition angle therebetween, and further allows the crown portion and the visor to bend at or near the transition area to adapt to and provide a comfortable fit for headwear worn on heads of different sizes and shapes.

[0050] In conventional headwear including a visor (also referred to herein as a hat, such as a baseball cap), the visor or visor is a separate component, i.e., separate from the crown portion, which is molded to fit the user's or wearer's head (including the top). For example, the visor is typically a separate component attached to the crown portion of the hat via stitching or other suitable connection. In contrast, headwear including one-piece or single-piece components as described herein (also referred to herein as single-piece molded components) is formed via a molding process, wherein the visor and crown, or at least a portion of the crown (i.e., the crown portion), are single, single-piece molded components. In particular, single-piece headwear is formed to include multiple layers, wherein at least one layer integrally forms both the crown (or a portion of the crown) and the visor of the hat.

[0051] refer to Figure 1A , Figure 1B and Figure 1C An example embodiment of a one-piece headwear or hat 100 is depicted, wherein the hat 100 includes a crown portion or crown 110 and a visor or visor 120 extending laterally from the front side or front end 112 of the crown 110. The crown 110 includes a hemispherical dome member, generally sized to fit a portion of a human head (i.e., covering the top of the head, including the forehead of the human wearer), while the visor 120 extends outwardly from the lower edge of the front end 112 of the crown 110. Figures 1A-1CAs shown, the crown defines a complete dome structure that surrounds the top portion of the wearer's head. In other embodiments as described herein, the crown may surround a portion of the wearer's head (e.g., as...). Figure 12A and Figure 12B The sun hat or visor depicted is open to expose the top portion of the wearer's head. Figure 1A and Figure 1B It can also be seen that the visor 120 may have a curved shape or profile, wherein the curvature is convex along the upper surface of the visor, and the convex curvature is defined transversely to the length dimension of the hat 100 (i.e., transversely to the linear dimension extending from the front end of the hat at the tip or free / end of the visor 120 to the rear end of the hat 114 and the crown 110).

[0052] The crown 110 of the hat 100 includes an inner surface that faces and aligns with the wearer's head when the hat 100 is worn. The opposing outer surface or outer surface of the crown 110 is exposed and may include identification (e.g., a sporting and / or corporate / enterprise logo, indicated as feature 240) and other molded features and / or other features formed on the outer surface during the molding / forming process of the hat 100 (e.g., molded buttons 115, one or more vents 116, and / or one or more molded creases or molded panel ridges 118, representing or mimicking the seams defining the crown panels). The visor 120 includes an upper side (including an upper fabric layer 220) corresponding to the exposed outer surface of the crown 110 and a lower side (including a lower fabric layer 230) corresponding to the inner surface of the crown 110. Similar to the features on the crown, the visor 120 may include features formed during the molding / forming process of the hat (e.g., molded grooves 125 representing mimicking seam lines, each groove including a general U-shape).

[0053] At the rear end 114 of the crown 110, a cutout section is formed and defined by a semi-circular edge 119, and an adjustment strap 130 extends across this cutout section at the lower edge of the crown. The adjustment strap 130 is secured to the crown 110 at the lower edge and the cutout section. The strap 130 may also include two opposing strap members that are releasably coupled to each other to facilitate adjustment of the crown's circumferential dimensions around the wearer's head based on the adjustable coupling of the strap members. The adjustable coupling of the strap members, configured at different intervals, can be achieved by any suitable coupling structure, including but not limited to hook-and-loop fasteners (Velcro brand), snap fasteners (e.g., rivets and slotted fasteners, such as...). Figure 1C (as shown), snap-on fasteners, etc.

[0054] Figure 2A The image depicts a cross-sectional side view of the hat 100. Figure 2B and Figure 2CPartial views are also depicted. The hat 100 comprises multiple layers that extend continuously between the crown 110 and the visor 120, thereby forming the hat, including the crown and visor, as a single integral unit or structure. In an example embodiment, the hat 110 includes an inner or intermediate foam layer 210, an outer or outer surface forming the crown 110 and an outer or upper fabric layer 220 above the visor 120, and an inner (i.e., head-facing) surface forming the crown 110 and an inner or lower fabric layer 230 below the visor 120. Each of the upper fabric layer 220, the intermediate foam layer 210, and the lower fabric layer 230 extends as a single continuous layer along the hat from the visor to the crown, such that the combination of these layers integrally forms the visor and crown of the hat without any seams or transitions between the individual layer portions along the upper / outer and lower / inner surfaces of the hat. In other words, compared to conventional hats that require multiple outer layers sewn together to form the crown and the connection between the visor and the crown, the hat described herein requires minimal or no sewing, particularly at the seamless transition between the visor and the crown / crown portion. While the thickness of each of the layers 210, 220, and 230 forming the hat can vary, each of these layers has a substantially uniform or constant thickness as it extends from the front end of the hat (at the leading or terminal edge of the visor) to the rear end of the hat (the rear end of the crown). However, it should be noted that any one or more of these and / or other layers forming the hat can have a thickness that varies along its length.

[0055] Binding material 250 (e.g., small pieces of fabric or other materials, such as binding tape) may be provided along the entire outer periphery of the aligned edges of layers 210, 220, 230 (including the front and rear edges where these layers terminate) to seal the cap at these edges (i.e., to prevent the peripheral edges of the layers forming the one-piece molded structure of the cap from being exposed). Binding material 250 may be folded over the peripheral edge portions of layers 220, 210, 230, etc., and secured in a suitable manner (e.g., by adhesive, welding, sewing, etc.). Thus, the intermediate foam layer 210 is encapsulated or included between layers 220, 230 and binding material 250 at the front and rear edges of the cap 100. The peripheral edges of layers 210, 220, 230 are also covered by binding material 250, which extends around the periphery of the cap.

[0056] In the example embodiment, each of fabric layers 220 and 230 may be composed of the same or similar materials, including but not limited to woven fabric materials, knitted fabric materials, nonwoven fabric materials, and embroidered fabric materials. Any suitable one or more types of yarns, filaments, and / or fibers may be used to form the fabric materials constituting fabric layers 220, 230, wherein the yarns, filaments, and / or fibers may be formed from natural materials (e.g., cellulosic materials such as cotton and / or bamboo, protein materials such as silk, wool, soybean, etc.) and / or synthetic polymer materials. Some non-limiting examples of synthetic polymer materials that may be used to form synthetic yarns, filaments, and / or fibers of fabric materials include polyolefin fibers (e.g., polyethylene, polypropylene, etc.), polyester fibers (e.g., polyethylene terephthalate or PET fibers and polypropylene terephthalate fibers), polycaprolactam fibers, polyhexamethylene adipamide fibers, acrylic fibers, acetate fibers, rayon fibers, polyamide (nylon) fibers, aramid fibers (e.g., Kevlar fibers), and any one or more selected combinations thereof.

[0057] In an example embodiment, one or more fabric layers may comprise polyester and / or elastomer materials (e.g., spandex). In another example embodiment, one or both of the upper and lower fabric layers may comprise a fabric material of about 85% polyester and about 15% spandex (215 g / m²), and the reinforcing fabric layer 415 may comprise a fabric of about 79% polyester and about 21% spandex (210 g / m²). The upper and lower fabric layers may have similar or different properties, such as elongation properties. For example, one fabric layer may have a greater degree of elongation or elasticity than the other fabric layer in one or more dimensions (e.g., along the length and / or width of the fabric layer).

[0058] The fabric material may also include any suitable additives that can alter or enhance the heat transfer properties of any or both of the fabric layers 220 and 230. For example, the lower fabric layer 230 (i.e., the fabric layer in the hat that faces and contacts the wearer's head) may be a cooling fabric with a higher surface area contact heat transfer rate than conventional fabrics. In embodiments, the cooling fabric comprises filaments and / or yarns with non-circular cross-sections (e.g., trefoil, rectangular, bow-shaped, or wavy). When woven into a fabric, filaments and / or yarns with modified cross-sections facilitate moisture transport and evaporation. Fabrics comprising filaments with non-circular cross-sections have an increased moisture diffusion rate compared to fabrics formed solely from filaments with circular or round cross-sections, which in turn enhances the fabric's evaporation effect.

[0059] In a further embodiment, the lower fabric 230 can be configured to have a high Qmax value (W / m). 2(For example, measured by one or more of the following test standards: FTTS FA 019, GB / T 35263, and CNS 15687 L3272). The Qmax value is an indicator of the rate of heat transfer of a fabric, representing the maximum amount of heat that can be transferred through one square meter of fabric per second. This evaluation tests the surface temperature of the fabric to indicate the instantaneous thermal sensation perceived when the material first comes into contact with the skin. A higher Qmax value indicates that heat moves more rapidly from the body to the fabric surface, resulting in a cooler feeling. In other words, fabrics with a higher Qmax rating have better cooling performance because they can transfer more heat away from the body. These fabrics help regulate body temperature by absorbing and dissipating excess heat and moisture, preventing sweat buildup, and providing a cool and comfortable surface. In a preferred embodiment, the lower fabric layer 230 has a Qmax value of 0.10 W / m². 2 Up to 0.50 W / m 2 A Qmax rating, for example, at least 0.1 W / m 2 Or higher, and preferably at least 0.13 W / m 2 To improve the Qmax value of the fabric, filaments with a higher Qmax value are selected. In other words, the fibers are formed from materials with a higher Qmax value. In embodiments, the filaments may be formed from polyester or nylon, each having a higher Qmax value than cotton. The Qmax value can be further enhanced by embedding cooling particles in the lower fabric layer. Cooling particles include, for example, titanium dioxide, gemstone, mica, graphene, and any combination thereof. In a more preferred embodiment, the filaments forming the lower fabric layer 230 comprise polyester filaments embedded with mica and having a wavy or cloud-like cross-section.

[0060] The lower fabric layer and / or any other layer of the cap may also be configured to impart suitable moisture permeability to the cap during use. In particular, a cap having the characteristics imparted to the lower fabric layer (and / or other layers of the cap) as described herein may have a moisture permeability of at least about 300 g / 24 h / m², or at least about 400 g / 24 h / m², or at least about 500 g / 24 h / m², or at least about 600 g / 24 h / m², or at least about 700 g / 24 h / m², or even or at least about 800 g / 24 h / m² or higher.

[0061] In a further embodiment, the fabric forming the hat (e.g., an inner fabric layer) may include a functional layer. A functional layer is an ink or other coating applied to the fabric that contains a material operable to alter the fundamental properties of the fabric. In an embodiment, the functional layer is a thermal management print configured to modify the temperature regulation and / or moisture management properties of the fabric. In a specific embodiment, the lower fabric layer 230 may include multiple components that provide thermal management or cooling properties to the fabric layer. For example, the lower fabric layer 230 may include any one or more components or reactive component systems (i.e., components that respond to temperature / temperature changes in the hat-wearing environment), including but not limited to coolants, latent heat agents, and heat dissipation agents.

[0062] In particular, the coolant of the system's reactive component can include an endothermic coolant, i.e., it creates a system that absorbs heat. For example, an endothermic coolant may have an enthalpy change in the range of -10 cal / g to -50 cal / g, or in the range of -20 cal / g to -40 cal / g. In this configuration, when the coolant comes into contact with water (i.e., the wearer's sweat), the coolant is able to cool the water (i.e., lower the water's temperature). Examples of coolants include one or more polyols, such as erythritol, lactitol, maltitol, mannitol, sorbitol, and xylitol (e.g., one or more of sorbitol, xylitol, and erythritol).

[0063] The latent heat agent of the reactive component of the system is capable of absorbing and releasing heat energy in the system while maintaining a substantially constant temperature. In an example embodiment, the latent heat agent may include a phase change material (PCM). Straight-chain hydrocarbons (e.g., paraffinic straight-chain hydrocarbons having 15-20 carbon atoms) are suitable as phase change materials. For example, the phase change material may be selected to undergo a phase change at a temperature close to (e.g., 1-5°C above or below) the average skin temperature of the hat wearer (i.e., a human wearer, e.g., 33-34°C). In this configuration, the phase change material begins to regulate temperature either when the hat is placed on the wearer's head or shortly after the wearer begins to heat up (e.g., in response to the commencement of any physical activity).

[0064] A heat-dissipating agent can provide a reactive component of the system to effectively conduct heat and / or direct heat from one location within the system (e.g., within a fabric layer) to another. In embodiments, the heat-dissipating agent has a high heat capacity, which determines how much the temperature of the heat-dissipating agent will rise relative to the applied heat. For example, the heat-dissipating agent is a silicate mineral, such as jade, for example, nephrite, jadeite, or a combination thereof.

[0065] When the system reactive component is used within the fabric layer 230, the mixture of components may include a coolant comprising 15% to 35% by weight of the system reactive component, a latent heat agent comprising 25% to 45% by weight of the system reactive component, and a heat dissipator comprising 25% to 45% by weight of the system reactive component. The system reactive component may also be provided in a polymeric adhesive material and dispersed in the lower fabric layer in any suitable manner, or even coated on the exposed surfaces of the lower fabric layer 230.

[0066] Previous embodiments provide heat transfer properties within one or more layers of the hat, suitable for warmer environments where it is desirable to provide cooling to the wearer's head. In further embodiments, the hat may also be equipped with a functional layer operable to promote heat retention to the wearer's head, for example, in cold or cooler climates.

[0067] For example, the lower fabric layer 230 may include a ceramic material provided in any suitable pattern along the exposed surface (i.e., the surface facing the wearer's head). This ceramic material may be provided, for example, as an ink printed on the exposed surface of the fabric layer, wherein the ceramic may include any of a variety of ceramics suitable for inclusion on the exposed surface of the fabric layer, including oxide ceramics and non-oxide ceramics. For example, the ceramic material may include one or more of silicon dioxide, zirconium carbide, alumina, or any other variety of ceramic materials.

[0068] The functional layer can also absorb heat radiated by the user and convert the energy into infrared radiation (e.g., far-infrared radiation) directed at the user. These materials are referred to as bioceramic materials. For example, a bioceramic composition includes a bioceramic material (as described above) and an adhesive that effectively disperses the components and / or adheres the temperature-reactive components to a substrate (e.g., yarns / fibers forming the substrate). The adhesive can be an elastomeric material with good elongation and tensile strength properties. Elastomeric materials typically have chains with high flexibility and low intermolecular interactions, as well as physical or chemical crosslinking to prevent the chains from slipping off each other when the material is under stress. In embodiments, polyurethane (e.g., thermoplastic polyurethane, such as polyester-based polyurethane) is used as the adhesive. In other embodiments, block copolymers having hard and soft segments can be used. For example, styrene-based block copolymers, such as styrene-ethylene / butene-styrene (SEBS) block copolymers, can be used.

[0069] These bioceramic materials include ceramic oxide materials and non-oxide ceramic materials, including but not limited to silicon oxides or silicon dioxide (e.g., SiO2), zirconium oxides (e.g., ZrO2), titanium oxides (e.g., TiO2), aluminum oxides (e.g., Al2O3), magnesium oxides (e.g., MgO), yttrium oxides (Y2O3), zirconium carbide (ZrC) and titanium carbide (TiC), and combinations thereof.

[0070] In the form of ink, the content of bioceramic material in the ink ranges from about 2% to about 50% or more by weight. For example, the content of bioceramic material in bioceramic ink may be at least about 2% by weight, at least about 5% by weight, at least about 25% by weight, at least about 30% by weight, but at least about 40% by weight, or no more than about 50% by weight. In another example, the content of bioceramic material in bioceramic ink may be from about 5% to about 15% by weight, or from about 8% to about 12% by weight (e.g., about 10% by weight).

[0071] The composition forming a functional layer (e.g., a thermal management or bioceramic printed layer) is applied to the fabric in a manner that maintains component integrity and preserves the properties of the substrate (textile or fabric). In embodiments, the composition is transferred to the substrate via a printing process. For example, the composition is transferred to the textile or substrate via a rotary gravure printing apparatus, which includes an impression roller, a gravure or etching roller, and a reservoir. The roller has recessed surface cells engraved / etched in the desired pattern. The reservoir holds the composition. The apparatus also includes a doctor blade operable to remove excess composition from the roller. In operation, as the roller rotates, a portion of the roller is immersed in the composition stored in the reservoir. The composition coats the roller and is trapped within the cells. The roller continues to rotate, passing the coated roller past the doctor blade, which removes excess composition from the roller. The textile is guided between the impression roller and the roller such that the inner surface of the substrate (e.g., the side of the garment facing the wearer) contacts the roller. Specifically, the impression roller applies force to the substrate, pressing the textile onto the roller to ensure uniform and maximum coverage of the composition. Surface tension pulls the composition out of the cells and transfers it onto the substrate. Once the composition is transferred, the coated textile can be passed through one or more heaters to evaporate the solvent, thereby drying the composition and forming a dried printed layer. If a thicker coating is required, multiple passes through a rotary gravure printing machine can be performed.

[0072] The application or printing of the functional layer can be of any suitable type, such as repeating and / or nested pattern fragments printed as layers on a fabric surface. Bioceramic materials can be printed as layers on a fabric surface in any shape (e.g., circular, polygonal, and irregular shapes). The pattern is a discontinuous pattern, including printed areas interrupted by unprinted areas, and vice versa. Printed areas refer to areas covered by the functional composition (e.g., applied as a coating, film, or print). Unprinted areas refer to areas without the functional composition (i.e., not covered by the composition), thus exposing the textile. Textiles include the textile itself, or textiles with other coatings besides the functional composition (e.g., antimicrobial coating, durable waterproof coating, etc.).

[0073] Generally, the pattern comprises an arrangement of printed segments separated by non-printed segments called hinges. Each segment and hinge can have any size suitable for its intended purpose. Furthermore, segments and hinges can be arranged into units or cells that define a repeating or random pattern across the entire textile surface. By way of specific examples, the functional composition printed pattern comprises substantially linear segments arranged in a spaced-apart and non-parallel manner to define selected angles (e.g., angles of 90° or greater, such as obtuse angles) between the linear segments. Additionally, units can include concentrically aligned or nested patterns of such linear segments. Nested patterns can include polygonal shapes (e.g., polygons with four or more sides, such as squares or rectangles, pentagons, hexagons, etc.) nested within the same or similar polygonal shapes. The linear segments can have the same or similar width and / or thickness, or, alternatively, can have different widths and / or thicknesses.

[0074] As an alternative (or complementary) to printing or applying bioceramic materials as a layer onto the surface of a fabric, functional materials can also be incorporated into the filaments, fibers, and / or yarns that form the fabric. Some examples of bioceramic fibers, filaments, or yarns that can be integrated into bedding components of a bedding system include, but are not limited to: polyethylene terephthalate (PET) fibers comprising one or more bioceramic particles (e.g., silica and / or alumina) embedded in a fiber core, such as fibers commercially available under the trade name CELLIANT® (Hologenix, LLC, California); polyamide (e.g., nylon 6,6) yarns incorporating bioceramic particles, such as bioceramic yarns commercially available under the trademark EMANA® (Solvay Group, Belgium); and combinations of cotton and bioceramic yarns, such as those commercially available from SAMINA® (Germany).

[0075] For example, yarns comprising bioceramic materials can be provided for forming woven, knitted, nonwoven, or any other type of fabric material. The quantity, type, and placement of the yarns comprising bioceramic materials in the fabric material can be selectively controlled to achieve the required amount of bioceramic material per unit fabric location (e.g., from about 0.5 g / yd² to about 30 g / yd²). Furthermore, the fabric material forming the panels or sheets of bedding components can include any selected number of interlaced yarn layers, with the bioceramic material yarns positioned at any selected location within the fabric material thickness.

[0076] The intermediate foam layer 210 may include any suitable foam material, such as polyurethane foam. Additionally, two or more foam layers may be provided as part of layers forming a textile laminate or a one-piece molded component of the hat. Each foam layer provided in the fabric laminate may include any suitable one or more types of open-cell and / or closed-cell foam material that provides sufficient cushioning and comfort for the intended use. In particular, open-cell thermoplastic foam may be used. Some examples of suitable foam material types for forming headwear include, but are not limited to, polyolefin (e.g., polyethylene or polypropylene) foam, ethylene-vinyl acetate (EVA) foam, and polyurethane (PU) foam. The thickness of the foam layers may vary depending on their location along the headwear. For example, a foam layer provided in the visor portion may have a greater thickness than the foam layer within the crown portion (and vice versa). In an embodiment, a foam layer with a thickness of approximately 6.0 mm is provided between the fabric layers. In a further example embodiment, the foam material has suitable heat transfer properties to facilitate heat transfer between the wearer's head and the surrounding environment, thereby keeping the wearer comfortable when wearing the hat (especially in warmer climates). In other embodiments, the intermediate layer may include materials other than foam. For example, the intermediate layer for textile laminates or one-piece molded components may include textile or fabric layers, such as woven fabric layers, knitted fabric layers, embroidered fabric layers, or nonwoven fabric layers.

[0077] Fabric layers 220 and 230 may be formed to have the same or similar thickness and / or the same or similar degree of stretchability. Similarly, the intermediate foam (or other material) layer 210 may have the same or similar degree of stretch or elongation properties as each of the fabric layers 220 and 230. In the example embodiment, one or more of the upper and lower fabric layers and the intermediate layer may be formed of suitable materials such that each layer (separate and independent of each other) has an elongation of at least about 40%, or at least about 50%, or about 50% to about 75%, or from about 50% to about 70% in the length direction of the cap 100 (i.e., from the free end or terminal of the visor 120 to the rear end 114 of the crown 110). One or more of the upper and lower fabric layers and the intermediate layer may also have an elongation of at least about 60%, or at least about 70%, or at least about 80%, or at least about 90%, or from about 90% to about 120%, or from about 93% to about 107% in the width direction of the hat (i.e., the direction transverse to the length direction of the hat). As used herein, the term "elongation" refers to the increase in dimension at the point of fracture or failure of a material when subjected to force or load in a particular direction, compared to its original dimension, according to the formula: (L 失效 - L 原始 / L 原始) x 100 calculation. Providing one or more layers with such elongation properties gives the cap suitable elongation or tensile properties.

[0078] The recovery rate of one or more of the upper and lower fabric layers and the intermediate layer in both the length and width directions may be at least about 60%, or at least about 70%, or at least about 80%, or at least about 85%, or greater than 85%. As used herein, the term "recovery rate" refers to the ability or extent to which a material relaxes back to its original size or a certain percentage thereof after being subjected to a tensile load and then the load is removed. Thus, a 100% recovery rate means that the material has relaxed back to its original length after being subjected to a tensile load, while a 90% recovery rate means that the material is 10% longer than its original length after the tensile load is released and it relaxes back to its original length. Providing recovery properties to one or more layers forming the hat also endows the hat with suitable recovery properties, enabling it to deform (e.g., expand) and then recover (e.g., shrink) its original shape when worn on the heads of wearers of different sizes or when bent, folded, or compressed in various forms.

[0079] As previously described, the hat 100 can be modified to include one or more additional layers between the upper and lower fabric layers 220, 230. For example, in other embodiments, the intermediate foam layer 210 can be modified or replaced with a textile or fabric layer (such as a knitted, woven, embroidered, or nonwoven layer) comprising various types of yarns that give the hat its structural character. For example, an intermediate fabric layer (replacing the intermediate foam layer or other than the intermediate foam layer) can be provided comprising molten and / or nonmolten yarns disposed thereon in one or more suitable locations. The molten yarns can be formed from polymers with lower melting points that may soften or partially melt when sufficient heat is applied during the molding process of forming the headwear (as further detailed herein) to reach or exceed the glass transition temperature of the lower melting point polymer. For example, the glass transition temperature of the molten yarns used to form the intermediate fabric layer may not exceed about 150°C (e.g., the temperature at which the molding process is performed). When cooled to ambient temperature, the lower melting point polymer recrystallizes and hardens. Non-limiting examples of molten yarns include thermoplastic polymer materials, such as low-melting-point polyesters, low-melting-point polyurethanes, or low-melting-point polyolefins.

[0080] Non-melting yarns are those with significantly higher glass transition temperatures and melting temperatures compared to melting yarns. During the molding process of headwear, non-melting yarns remain solid (i.e., do not soften or partially melt). In other words, the glass transition temperature of non-melting yarns can be higher than the temperature applied during the hat molding / forming process. Cross-yarn in one or more areas of the fabric layers can include both melting and non-melting yarns, such that during molding, the melting yarn partially melts, solidifies, and fuses with the non-melting yarn at its cross-section. This fusion of melting and non-melting yarns at selected cross-yarn locations results in a stiffening of the fabric structure, which in turn imparts structural integrity to the headwear along its contours after the molding process.

[0081] In a further embodiment, the upper and / or lower fabric layers can be formed using molten and non-molten yarns, wherein the molten yarns melt during molding and fuse with non-molten yarns and / or other molten yarns to enhance the structural integrity of the headwear at one or more desired locations. Furthermore, one or more textile layers of the headwear (e.g., a middle fabric layer, an upper fabric layer, and / or a lower fabric layer) can be formed entirely of molten yarns, which, when molded, bond or fuse with other intersecting molten yarns due to the melting or partial melting of the molten yarns during molding. The quantity, type, and amount of molten yarns, with or without non-molten yarns, can be selected based on the required stiffness level of a particular textile layer of the headwear, which imparts the required structural integrity to the headwear at one or more locations through yarn fusion at intersecting yarn locations within the fabric layers during one-piece molding of the headwear.

[0082] In an example embodiment, the thickness of each of the upper and lower fabric layers 220, 230 and the intermediate foam (or other material) layer 210 may range from about 0.25 mm to about 7 mm, or from about 0.50 mm to about 5 mm. In an example embodiment, the thickness of the lower fabric layer 230 may range from about 0.25 mm to about 0.75 mm (e.g., about 0.50 mm), the thickness of the upper fabric layer may range from about 1.5 mm to about 2.0 mm (e.g., about 1.8 mm), and the thickness of the intermediate foam layer 210 may range from about 1 mm to about 10 mm, or from about 2 mm to about 8 mm, or from about 2 mm to about 5 mm. After the cap (via compression molding) is formed, the layers are compressed and bonded together, resulting in a total thickness of all three layers 210, 220, 230 ranging from about 1 mm to about 3 mm, or from about 2 mm to about 2.5 mm.

[0083] One or more internal structural support members may also be disposed within the textile laminate or one-piece molded component forming the headwear article. The one or more internal structural support members may be formed from any suitable type of material that deforms during compression molding and provides resilient structural support for the headwear article at multiple locations. The material forming the internal structural support member may have a desired hardness value greater than the hardness value (e.g., Shore A hardness) of the material used to form the foam and fabric layers of the textile laminate. Some examples of materials that can be used to form the internal structural support member include, but are not limited to, polyurethane, polyolefins, polyamides (e.g., nylon), ethylene-vinyl acetate (EVA), etc. In an example embodiment, one or more internal structural support members are formed from a thermoplastic polyurethane (TPU) material, such as TPU material commercially available from Chemex Ltd. During the formation of the textile laminate or one-piece molded component, the internal structural support member may be formed from a non-foamed flat sheet that is shaped during compression molding. In embodiments, the structural support member has a Shore A hardness from about 40 to about 90, preferably less than 70 Shore A. Alternatively, the internal structural support can be formed from a starting material comprising a powder composition which is fused and hardened into a single, one-piece molded component before or during the compression molding process. The thickness of the internal structural support can range from about 0.2 mm to about 2.0 mm (e.g., about 1.0 mm).

[0084] In an example embodiment, the structural support may be in the form of a reinforcement member or a reinforcing plate 310, which is encapsulated or included within the visor 120 of the cap 100. The reinforcing plate 310 adds some rigidity or reinforcement strength to the visor 120 and optionally also adds rigidity or reinforcement strength to a portion of the crown 110. The reinforcing plate 310 is made of a rigid polymer or plastic material (e.g., a non-foamed material such as polyamide (e.g., nylon) or polyurethane, or other suitable material (e.g., rigid foam material) whose hardness or hardness gauge value (e.g., measured by a Shore hardness tester) is greater than the hardness or hardness gauge value of each fabric layer 220, 230 and foam layer 210. The plate 310 also does not have the same elongation properties and is therefore not similar in elongation to the fabric and foam layers that extend entirely between the front and rear ends of the cap. The reinforcing plate also has suitable dynamic flexibility. The reinforcement layer 310 is designed to be flexible and resilient to facilitate bending under forces or loads applied to the board and to return to its original relaxed shape after the load is removed. The board 310 is located between the intermediate foam layer 210 and the lower fabric layer 230. In an alternative embodiment, the reinforcement layer 310 may be located between the intermediate foam layer 210 and the upper fabric layer 220. The reinforcement board 310 may optionally include a series of through-holes or perforations throughout the board to reduce its weight and provide adequate ventilation (e.g., airflow) along and through the visor 110 (see, for example, as described herein). Figure 3A and Figure 3B ).

[0085] like Figure 2C As shown, the reinforcing plate 310 does not extend the entire length of the visor 120. Instead, the plate 310 extends to a selected distance D (e.g., at least 3 mm) from the transition between the visor 120 and the crown 110. In another embodiment, the reinforcing plate 310 may extend substantially the entire length of the visor 120 and terminate at or slightly before the transition area between the visor and the crown, so as not to extend around the transition area into a portion of the crown. In a further embodiment, the plate 310 may extend beyond the transition, from the visor portion into the crown portion (so as to extend along the transition area from the visor to the crown, see, for example, Figure 3CThe plate is three-dimensional and appropriately angled along the transition area between the visor and crown to facilitate cushioning and flexing of the visor, while providing a degree of rigidity but also sufficient flexibility when the hat is worn. In one embodiment, the rear portion of the plate curves upward at an angle similar to the transition. In embodiments where the reinforcing plate extends beyond the transition between the visor and crown, the portion of the reinforcing plate extending around the transition, and the portion on each side of the transition, may have a tapered construction or a reduced thickness compared to other portions of the reinforcing plate. For example, the reduction in thickness of the reinforcing plate at the portion extending around the transition between the visor and crown relative to the maximum thickness of the reinforcing plate at other portions may be at least about 5%, or at least about 10%, or at least about 20%, or at least about 30%, or at least about 40%, or at least about 50%.

[0086] The sweatband layer 320 may also be provided along the interior or lower surface portion of the hat or the exposed surface portion of the fabric layer 230 to cover the transition between the visor 120 and the crown 110 (i.e., the area where the hat transitions between the visor and the crown). The sweatband layer 320 may be made of any suitable fabric or other material with suitable softness, as it provides a connection between the hat and a portion of the wearer's forehead when the hat is worn. The sweatband layer 320 may also have suitable wicking or moisture-wicking properties to absorb moisture or sweat from the wearer's forehead during use. For example, the sweatband layer may wick moisture from the lower surface of the hat by a wicking distance of 100 mm or more within 30 minutes (based on a droplet wicking distance test). The sweatband layer may be further configured to have tensile or elongation properties similar to those of the fabric layers 220, 230 and the foam layer 210. In an example embodiment, the sweatband layer comprises a polyolefin or polyurethane material with suitable wicking properties. For example, the sweatband layer can have suitable hydrophilic properties to effectively wick or absorb moisture from the contact surface (e.g., the forehead of the hat wearer).

[0087] The hat 100 is formed as a single, integral structure or unit with multiple layers and few or no seams. Seams could create hard and / or rough surface areas that could rub, chafe, or irritate the wearer's forehead skin. Forming the hat as a single, integral or one-piece structure is achieved through a single-step molding process in which all layers are formed together, with the core layer bonded together and adhered to each other by the molding process. (Reference) Figure 3A Each layer can be provided in its own shape or form, and then stacked together in the arrangement that forms the hat 100, as shown in the cross-sectional views of Figures 1-2. Each of the foam layer 210 and the fabric layer 220 may include an arcuate or concave cut-out section at its respective rear end, corresponding to the arcuate cut-out section 119 of the rear end 114 of the hat 100 during hat formation (e.g., ...). Figure 1C(As shown). The front edge of each of layers 210, 220, and 230 is rounded or convex to correspond to the front end / free end or terminal edge of the front end of the cap 100 / visor 120 during cap formation. Each of layers 210, 220, and 230 may also have a generally planar shape or construction before molding. The reinforcing plate 310 has a concave or arcuate profile at its rear edge, generally corresponding to the curved shape of the transition between the visor and the crown during cap formation. The plate 310 also has a rounded convex profile or shape at its front edge, corresponding to the rounded convex profile of the front edge of each of layers 210, 220, and 230. The sweatband layer 320 has a generally arcuate shape to correspond to the shape of the transition between the visor and the crown during cap formation. Each of the plate 310 and the sweatband layer 320 may also be generally planar before molding into the cap 100.

[0088] Although the embodiments of Figures 1-2 have the following characteristics: Figure 3A The layer orientations shown are (e.g., vertical orientation, or from upper fabric layer 220 to lower fabric layer 230), but it should be noted that other embodiments of the hat may include any other suitable layer orientations. For example, as previously described, the reinforcing plate may be disposed above (i.e., closer to the upper fabric layer) or below (i.e., closer to the lower fabric layer) the intermediate (foam) layer. Furthermore, any one or more additional layers may be disposed inside the hat (e.g., between the upper and lower fabric layers) or integrated as part of the hat. In one embodiment, a hat with a construction similar to that shown in Figures 1-3 may be provided, but with another intermediate (e.g., foam) layer disposed below the reinforcing plate. In other words, the reinforcing plate may be disposed or sandwiched between the first intermediate (e.g., foam) layer and the second intermediate (e.g., foam) layer.

[0089] As previously mentioned, the reinforcing plate may also include further features, such as providing perforations or through holes in selected portions of the reinforcing plate. An example implementation of the reinforcing plate 310A is as follows: Figure 3B As shown, the perforation or through-hole 315 extends along a selected surface area of ​​plate 310A (e.g., as shown in the figure). Figure 3B The through-hole 315 (exceeding 50% of the surface area) penetrates the plate 310A. This through-hole 315 reduces the weight of the plate 310A and provides ample ventilation (e.g., airflow) along and through the lip 110. In a further embodiment ( Figure 3CThe hat can also be provided with a reinforcing plate 310B, which includes a through-hole 315 and a curved portion 312 extending beyond the transition region TR between the visor 120 and the crown 110. In this embodiment, the plate 310B is three-dimensional and appropriately angled along the transition region between the visor and the crown to facilitate cushioning and flexing of the visor, while providing a degree of rigidity but also sufficient flexibility between the visor and the crown when the hat is worn. Furthermore, when molding the one-piece parts of the hat (including the upper and lower fabric layers, the middle (foam) layer, and the plate), the through-hole 315 of the plate 310B allows a portion of the middle (foam) layer to extend through the through-hole (e.g., ...). Figure 3C (As shown). This enhances the strength and rigidity of the visor and securely holds the reinforcing plate in place, preventing any slight or floating movement within the visor.

[0090] Compression molding processes for forming fabric laminates or one-piece molded components for headwear articles include a molding method in which molding material comprising layers is first placed in an open, heated mold cavity. The mold is closed using an upper mold force or plug component, applying pressure to force the material into contact with all mold areas while maintaining heat and pressure until the molding material solidifies. The temperature and pressure used during compression molding depend on the material used to form the layers within the fabric laminate, where softening of one or more layers is required to ensure proper adhesion between the layers during compression molding. In particular, softening of one or more layers involves heating to a temperature below the melting point of the material forming the layers (e.g., a softening temperature at least about 20°C lower than the melting point of the material forming the layers). Example softening temperature ranges used during compression molding can be from about 130°C to about 200°C (e.g., from about 140°C to about 190°C).

[0091] A mold can be provided, which is appropriately configured and sized to receive layers 210, 220, 230, 310, 320, and these layers are bonded together by heat and / or compression treatment within the mold to form a single integral composite structure defining a hat including a crown and a visor. Example embodiments of a mold comprising two parts (e.g., a clamshell mold) are provided. Figure 4A , Figure 4B , Figure 4C , Figure 4D and Figure 4EAs shown. Specifically, mold 400 may include a shell structure having two shell portions, a first shell portion 402 and a second shell portion 404. Each shell portion may include a suitable profile to mold the layers into the shape of a crown and a visor during the molding process. For example, the second shell portion 404 may include a circular or convex crown forming portion 420 corresponding to the crown of the hat to be formed, and a flat or slightly curved visor forming portion 425 corresponding to the visor of the hat to be formed. The first shell portion 402 may have a profile consistent with the lower shell profile, such that the layers are molded into the desired hat shape within the mold. In particular, the first shell portion 402 includes a concave crown forming portion 410 and a flat or slightly curved visor forming portion 415, the concave crown forming portion 410 being aligned and corresponding to the convex crown forming portion 420 of the second shell portion 404, and the visor forming portion 415 corresponding to portion 425 of the second shell portion 402, thereby defining the profile of the headwear item (hat 100) when the first shell portion and the second shell portion are pressed together.

[0092] Each shell portion may include recesses and / or protrusions along its internal molded surfaces (i.e., molded surfaces facing each other), these recesses and / or protrusions being appropriately aligned and sized to emboss marks or shapes, appearing as raised three-dimensional structures and / or grooves or recesses, onto the outer and / or inner surface portions of the cap (i.e., along the exposed surface portions of fabric layers 220 and 230). For example, Figure 4B and Figure 4C The cap 100 is formed with molded buttons 115 and one or more molded creases or ridges 118 (also referred to as fold lines), and molded U-shaped grooves 125 are also provided, which resemble seams along the brim 120 (e.g., making the molded three-dimensional features visible along the fabric layer 220). This is achieved by providing protrusions and / or corresponding recesses at molded surface locations on one or both of the first shell portion 402 and the second shell portion 404. The U-shaped grooves 125 formed along the brim 120 of the cap 100 (along the exposed surface portion of the upper layer 220) can be continuously aligned with each other in a nested construction or nested pattern (as shown, e.g., in...). Figure 1B middle).

[0093] The molded groove 125 (representing a simulated seam line) along the visor 120 is formed by a plurality of continuously aligned ribs or protrusions 450 located on and extending outward from the mold surface of the visor forming portion 415 of the first housing portion 402. The ribs or protrusions 450 are curved or arcuate, thus forming a curved or arcuate molded groove 125 along the upper fabric surface of the visor 120 during the formation of the visor 100. If it is desired to form a corresponding molded groove representing a simulated seam line along the lower fabric surface of the visor, the second housing portion 404 may optionally include curved or arcuate protrusions (not shown) along the mold surface of the visor forming portion 425, which are properly aligned with the protrusions 450 of the first housing portion 420.

[0094] The molded button 115 is formed by providing a curved or concave recess or indentation 430 on the crown-forming surface 410 of the first housing portion 402, and a corresponding curved or convex protrusion 440 aligned along the crown-forming surface 420 of the second housing portion 404. The dimensions of the indentation 430 and the protrusion 440 correspond to each other to facilitate the formation of the molded button 115 extending an appropriate distance from the curved convex profile of the crown portion of the hat 100.

[0095] The visor forming portions 415 and 425 of the first and second housing portions 402 and 404 can have corresponding profiles to form the hat 100, such that the visor 120 has a convex curvature transverse to the length dimension of the hat (e.g., Figure 1A and Figure 1B (As shown). Specifically, the visor forming portion 415 of the first housing portion 402 may have a slightly concave curvature that is transverse to the length of the mold 400; while the visor forming portion 425 of the second housing portion 404 may have a slightly convex curvature that is transverse to the length of the mold and corresponds in alignment with the concave curvature of the first housing portion 402. This can result in the formation of a hat with a curved visor, as shown, wherein the molding process forms the curved shape of the visor, which remains in this fixed curved shape after the hat is formed.

[0096] The layers can be appropriately arranged within the compression mold to form a shape such as... Figure 2A The hat shown is a stacked, single-piece structure. Now refer to... Figures 4A-4E and Figure 5 The flowchart describes the molding process for forming a single-piece headwear item (e.g., hat 100) as shown in Figures 1 and 2.

[0097] The initial step (step 510) provides layers for forming the cap 100, these layers having a generally planar shape, with cut sections forming curved edges and suitable dimensions, as described above and as follows. Figure 3AAs shown. For example, the upper and lower fabric layers 220, 230 are generally planar and are formed (e.g., via knitting, weaving, embroidery, forming a nonwoven structure, etc.) and shaped to have a curved front edge and a rear edge with a slit concave portion. The intermediate (e.g., foam) layer 210 may also be generally planar and formed in the same or similar shape as the fabric layers, while the sweatband layer 320 and / or any other layer are generally planar and shaped as desired to cover an area of ​​the cap. The reinforcing plate 310 may also have a generally planar shape, as described herein and Figure 3A The curved edge portion and dimensions are shown. The material used to form the reinforcing plate can be prepared by injection molding or die cutting (e.g., cutting TPU plastic material), or formed from a powder composition into a solid part (e.g., a solid TPU part) (heating / melting the powder composition to form a generally planar or one-piece solid component with a pre-formed shape).

[0098] The generally planar layers are stacked within the mold 400 (step 520) and located between the first housing portion 402 and the second housing portion 404, wherein the order of the layers is from the second housing portion to the first housing portion (e.g., ...). Figure 4A (As shown): sweatband layer 320, fabric layer 230, reinforcing plate 310, intermediate foam layer 210, and fabric layer 220. Each layer can be sequentially laid on the molded surface of the second shell portion 404, properly aligned along the molded surface of the second shell portion, and in a continuous order from the inside of the hat to be formed or towards the head to the outside. It is worth noting that by placing each layer sequentially on the second shell portion, the layers can be stacked in a specified order.

[0099] The layers are further placed in a stacked orientation within the mold such that the elongation properties of each layer correspond to the dimensions of the hat to be formed (i.e., the elongation properties of one or more layers are aligned within the mold to correspond to the length and width dimensions of the hat to be formed). For example, the layers may be placed in a stacked orientation within the mold such that at least one of the upper fabric layer, the lower fabric layer, and the middle layer has an elongation of about 50% to about 75% in the mold direction corresponding to the length direction of the head-wearing item, and an elongation of about 90% to about 120% in the mold direction corresponding to the transverse direction of the length direction of the head-wearing item.

[0100] exist Figures 4A-4EIn the illustrated embodiment, the first shell portion 402 is the upper shell portion, and the second shell portion 404 is the lower shell portion. However, it should be noted that the first and second shell portions can also be inverted, such that the first shell portion 402 is the lower shell portion and the second shell portion 404 is the upper shell portion. In such an embodiment, the layers can be placed on the first shell portion 402 in the reverse order of the previously described layer sequence (i.e., the first layer is the fabric layer 220, then the foam layer 210, etc.). The first shell portion, the second shell portion, and / or one or more layers may include suitable markings or identifiers to precisely position the sweatband layer 320 and the plate 310 at least relative to the fabric layers 220, 230, and the foam layer 210 within the mold, thereby achieving the desired alignment between the layers when molded or fused together during the molding process. Optionally, the edging material 250 may also be placed in the mold prior to the molding process to wrap the peripheral edge portions of the layers. Alternatively, the binding material 250 can be attached to the perimeter edges of each layer in any other suitable manner (e.g., welding or bonding) after the cap has been formed in the mold.

[0101] After all layers are placed in the second shell portion of the mold, the first shell portion 402 is placed on top of and properly aligned with the second shell portion 404, and the first and second shell portions are forced or pressed against each other (step 530), and the layers are pressed together via the opposing molding surfaces of the shell portions. Figure 4D During compression, appropriate compressive forces and / or appropriate heat are applied to the layers within the mold to form a cap comprising a one-piece molded component having a three-dimensional shape and including a crown and visor having the outlines and shapes shown in the figures. In an example embodiment, the layers placed in the mold are thermally compressed at a temperature of about 150°C, or at least about 175°C, or 200°C or higher, for a sufficient time (e.g., about 120 to 160 seconds). An example softening temperature range used during compression molding may be about 130°C to about 200°C (e.g., about 140°C to about 190°C).

[0102] Then the first shell portion and the second shell portions 402 and 404 of the mold 400 are separated (step 540), and the molded layers retain the shape of the molded surface contour within the shell portion to form the cap 100 (see Figure 4EThe hat 100 includes the shape of a crown 110 and a visor 120 (the visor having a curved profile transverse to its length and the length of the hat). At step 550, a strap 130 is secured to the rear end of the hat 100 (e.g., via sewing, gluing, etc.). Additionally, binding material 250 can be provided along the outer peripheral edges of each layer forming the hat after the molding process. Alternatively, the binding material can be provided at a suitable location in the sequential order of the layers within the mold before the molding process, such that during molding, the binding material is glued or secured to each layer along the peripheral edges of the hat (thus avoiding additional processing steps, as the binding material can be added during the molding step).

[0103] As a result of the molding process, the layers are pressed, molded, and bonded or glued together to define a single integral composite structure or textile laminate. As previously described, the formed hat comprises layers 210, 220, and 230 that extend the entire length and width dimensions of the hat 100, such that each section of the hat (extending the entire dimensions of the crown 110 and the visor 120) includes each of these layers 210, 220, and 230. The molding process compresses and glues the layers together, resulting in a reduction in the thickness of each individual layer after the molding process. Thus, the majority of the hat 100 is formed without any stitches or seams or individual panels joined together and not extending the entire size of the hat. In particular, the outer or exposed surface of the hat, defined by the exposed surfaces of the fabric layers 220 and 230, is defined by a single layer of material. In other words, the hat does not include portions or panels sewn together or having external seams along the majority of the exposed surface area of ​​the hat. Furthermore, the crown and visor of the hat are thus formed by a single, integral composite structure (i.e., the crown and visor are not separate parts connected to each other by any stitches or seams).

[0104] The compression molding process forms the outline portion of the headwear, which is shaped into the molded portion and retains and maintains its shape. In particular, the compression molding process forms a single molded body defining the curved visor portion and the annular or dome-shaped crown portion, which has the same or different numbers and / or types of material layers.

[0105] The materials used to form the hat include an intermediate foam layer 210 that extends the entire length of the hat (from the front edge of the front of the hat / visor 120 to the rear of the hat / crown 110), as well as an upper fabric layer 220 and a lower fabric layer 230. Combined with a molding process that forms the hat as a basic one-piece molded component (rather than the crown and visor being separate components connected to each other), the hat has a very flexible, "memory" or shape-preserving shape that allows the hat to essentially orient back to its original shape and construction after being bent or deformed in any number of compressed forms.

[0106] For example, a hat can be compressed or rolled into a smaller space or volume shape, such as a ball (e.g., by squeezing the parts of the hat together with one or both hands) or folded in any one or more ways (e.g., to fit into a small compartment or space, such as a coat or trouser pocket), and the hat remains in this compressed shape under the action of a holding force. When the compressive force applied to the hat is released (e.g., when the hat is removed from a compartment or pocket), the hat expands and / or redirects back to its original (i.e., initially molded) shape. This facilitates easy storage and transport of the hat when not in use, and the hat's flexibility allows it to easily conform to the expansion or contraction around the wearer's head (e.g., when using the adjustment strap 130), regardless of head size and shape.

[0107] When using textile material layers comprising molten and / or non-molten yarns (e.g., upper and lower fabric layers and / or one or more intermediate fabric layers), as a result of the molding process, the molten yarns fuse or bond with other molten and / or non-molten yarns at selectively interlaced locations on the textile material layer. This causes the textile material layer to stiffen, thereby providing structural integrity for headwear / hats and also enhancing their "memory" or shape-retention properties, i.e., prompting the hat (or other headwear) to return to the original shape formed during the molding process, even after the hat has significantly deformed from its original shape.

[0108] Furthermore, in embodiments where at least the reinforcing plate includes perforations or through-holes (e.g., plate 310A or plate 310B), as a result of the molding process, portions of the intermediate layer (e.g., foam layer 210) can be forcibly extended into or even partially through the through-holes (such as...). Figure 3C (as shown), so that the reinforcing plate can be securely fixed inside the visor of the hat.

[0109] Traditional hats consist of a crown section and a cap section, which are fixed together to form the hat. This typically results in numerous layers folding at the joint or connection between the visor and the crown. This further results in one or more hard seams or edges forming on the inner surface of the hat at the transition between the visor and the crown (due to the combination of many layers required to connect the visor and the crown), and this transition is further located at a position corresponding to the wearer's forehead. This hard seam / hard edge contacting the wearer's forehead can cause irritation and discomfort. In contrast, the one-piece hat formed by the molding process described in this article has no folded layers at the transition between the visor and the crown (i.e., the layers extend continuously through the transition between the visor and the crown, where there are no folds / seams / hard edges).

[0110] The compression molding process may also include mold portions with patterned recesses and / or protrusions that, when forming the fabric laminate, define corresponding “mirror-image” patterns of recesses and / or protrusions along the surface of the fabric laminate defining the outer surface portion of the headwear. This facilitates the formation of macrostructures (the dome shape of the crown and the curvature of the visor) and / or microstructures on the inner and / or outer surfaces of the headwear. For example, the crown portion and / or visor portion may include an outer surface pattern forming contours of uneven recesses and / or raised ridges. For example, protrusions may be formed on the outer surface portion of the headwear via the compression molding process, providing a functional or decorative shape in a designated area of ​​the headwear. When positioned on the inner surface of the headwear, protrusions can act as spacers to create air gaps or channels between the headwear and the user's head, allowing airflow within the channels. The protrusions are integrated into the headwear and shaped by the mold portions. The protrusions can be any size and shape suitable for their stated purpose, and can be arranged in any predetermined pattern along a portion or the entire headwear.

[0111] Specifically, one or both of the first and second shell portions of the mold may include recesses, indentations, and / or protrusions in suitable locations to imprint corresponding features along the outer surface portion of the hat during the molding process. In the example embodiments of the hats of Figures 1 and 2 and the mold of Figure 4, the first shell portion of the mold includes appropriately sized circular or concave recesses (…). Figure 4C This concave recess facilitates the formation of a molded button 115 on the top of the crown 110 of the hat 100 during the molding process. The molded button 115 is defined by portions of the upper fabric layer 220 and the intermediate foam layer 210, which are pressed into recesses or indentations 430 on the molding surface 410 of the first housing portion 402 of the mold during the molding process. Figure 2A and Figure 2B As shown, a molded button 115 can be formed via a molding process such that all three layers (upper fabric layer 220, middle foam layer 210, and lower fabric layer 230) are deformed to form curved convex protrusions along their respective upper (i.e., upward) surfaces. These surfaces define the molded button 115 (i.e., the upper convex surfaces 221, 211, and 231 of the upper fabric layer 220, middle foam layer 210, and lower fabric layer 230, respectively). Figure 2B(As shown). Furthermore, the lower fabric layer 230 includes an exposed concave surface 233 at the location of the molded button 115. These convex and concave surfaces are formed because corresponding convex protrusions 440 on the molded surface of the second housing portion 404 force each layer into the indentation 430 of the first housing portion 402. Thus, the curvature formed in each of the layers 220, 210, and 230 by the molding process forms the molded button 115, which has a dome-shaped or raised (e.g., hemispherical) three-dimensional shape along the exposed portion of the upper layer 220 (e.g., at or near the apex of the crown 110).

[0112] Similarly, the molded groove 125 along the upper surface of the visor 120 of the hat 100 is formed during the molding process by protrusions 450 on the visor forming portion 415 of the first shell portion 402 being pressed into the upper surface of at least the upper fabric layer 220 when the shell portions 402, 404 are closed. The combination of pressure and heat creates these indentations, which remain after the shell portion is removed from the molded hat, thus defining the arcuate or curved molded groove 125 along the upper surface of the visor 120 (as shown, for example in...). Figure 1A middle).

[0113] The molded button 115 at the crown 110 and the molded groove 125 at the visor 120 create a visual effect similar to a conventional hat, in which buttons are attached (e.g., sewn or glued) to the upper surface of the crown, and the stitches forming the seam are provided in a curved manner along the visor. Similarly, vents 116 mimicking seam lines and molded or panel ridges 118 can be formed at least on the surface of the fabric layer 220 along the location of the crown 110 during the molding process to provide features that create a visual effect similar to a conventional hat including actual panel seams and / or vents. These additional features can also be achieved by providing suitable protrusions and / or indentations within one or both of the upper and second shell portions to achieve the desired formation in a portion of the hat. For example, a vent 116 can be formed along the crown 110 using stamped protrusions on one or both shell portions of the mold, so that an opening (thus forming a vent) is formed on the crown when the shell portions are closed and the molding process is under suitable pressure and temperature. Although not shown, additional ventilation holes or openings may be provided in the visor of the hat (e.g., to provide airflow through the hat in selected locations).

[0114] Therefore, the ventilation hole 116 can be an actual through-hole or perforation extending through at least the upper fabric layer 220 (and possibly even into and / or through one or both of the intermediate foam layer 210 and the lower fabric layer 230). Perforations formed in one or more layers of the hat can provide suitable ventilation (e.g., airflow) to enhance airflow and heat transfer (e.g., cooling) between the wearer's head and the surrounding environment. As previously described, the reinforcing plate 310 may include perforations to allow ventilation / airflow through the plate. Such perforations can extend not only through the plate 310 but also through other layers (e.g., layers 220, 210, 230), where the perforations are interconnected to allow ventilation or airflow entirely through the perforations through the visor 120. Slightly raised protrusions or ribs (e.g., arcuate ribs) may also be provided at suitable locations on the first shell portion, embossing arcuate grooves on the visor 120 to define molded grooves 125 that resemble and provide the visual effect of actual seams present in the visor of a conventional hat.

[0115] The combination of materials used to form the hat, including fabric and foam materials, and the vents (e.g., air vents formed in the crown and / or any other vents, such as vents in the visor) and the formation of the layers (seamless or seamless or folded layers), can provide the hat with effective airflow to enhance heat transfer (e.g., cooling) between the wearer's head and the surrounding environment during use. In some example embodiments, the hat may include any suitable number of vents that extend along the crown and / or visor through all layers of the hat (i.e., extending through and through all layers, including the upper fabric layer, the middle foam layer, and the lower fabric layer) to provide the hat with at least about 200 CFM (cubic feet per minute), or at least about 250 CFM, or at least about 300 CFM, or at least about 350 CFM or higher, or even at least about 375 CFM or higher airflow / breathability. This is a significant improvement compared to the approximately 50 CFM of breathability typically allowed by conventional hats.

[0116] Compression molding allows the formation of a visor portion with different mechanical properties from the crown portion. Compression molding also allows the formation of headwear components with a one-piece construction that is seamless and stitchless (e.g., excluding separate parts held together by stitches).

[0117] Furthermore, the mold and molding process used to form the hat, as well as the material layers described in this paper, can give the one-piece hat a rounded transition that allows the hat to bend at the transition between the visor and the crown, thereby reducing the contact pressure point between the hat and the wearer's forehead when wearing the hat.

[0118] In traditional hats, especially those where the visor and crown are separate components connected to each other, the transition area between the visor and crown is typically defined by an angle of approximately 90° (measured along the longitudinal section of the hat). The connection between the visor and crown is also very rigid, and the hat has little or no flexibility in the transition area when worn by wearers with different head shapes.

[0119] In the molded hat 100, which is formed as a one-piece structure, the hat can be configured such that the transition area between the visor 120 and the crown 110 is defined by an obtuse angle (much greater than 90°) and a rounded angle. (Reference) Figure 6 The transition area is typically defined by an angle between the visor 120 and the crown 110, indicated by a dashed line along the upper fabric layer 220, wherein the transition angle α is at least approximately 100°, or at least approximately 110°, or at least approximately 120°, or 130° or even greater. The transition area is further rounded and defined by a portion of circle A (i.e., the rounded transition area is tangent to circle A), wherein the radius R of circle A is approximately 3 mm or greater, for example, from approximately 5 mm to approximately 20 mm.

[0120] The transition area features a rounded construction defined by an obtuse transition angle, and the combination of continuous layers within the transition area (i.e., no folded seams or edges) promotes a suitable level of flexibility in the hat. This results in a degree of curvature along the transition area (e.g., ...). Figure 6 As shown by the dashed lines C1 and C2, this illustrates the bending deformation of the crown 110 at its front end where it connects to the visor 120, up to or near the button 115, to align and fit the hat against the wearer's forehead while minimizing or preventing pressure points on the wearer's forehead. This can be referenced... Figure 7A , Figure 7B , Figure 8A and Figure 8B Further evidence. These drawings schematically depict the brim of a traditional hat ( Figure 7A and Figure 7B How to accommodate different head sizes / shapes (labeled as narrow, standard, and wide) and Figure 1A The brim of the hat ( Figure 8A and Figure 8B How to adapt to comparisons of the same or similar head size / shape.

[0121] like Figure 6 As shown (dash lines C1 and C2 represent changes in the hat's outline) and Figure 8A and Figure 8BAs shown, the crown 110 and / or visor 120 of the hat 100 can be slightly deformed or reshaped to accommodate different head sizes of the wearer. Furthermore, when the hat is worn by wearers with different head sizes and / or shapes, the transition area between the visor 120 and the crown 110 is defined by an arc curvature 810 extending transversely between the two sides of the hat, representing the front and rear sides (see...). Figure 8A It can deform or change in the arc angle (e.g., causing the visor and / or crown to stretch to fit different head sizes / shapes).

[0122] refer to Figure 7A and Figure 7B Traditional hats may create hard edges or pressure points that exert greater pressure on the wearer's forehead depending on their head size / shape. This is due to the relative inflexibility or lack of flexibility of the crown and / or visor, particularly along the curve defined by the transition area between the crown and visor (e.g.,...). Figure 7A As shown in curve 710, the arc and the visor are on the same plane, further as... Figure 7B (As shown in TR in the text), based on different head sizes / shapes. Regardless of the wearer's forehead shape, the curvature or angle of the arc defining the transition between the visor and crown of a traditional hat remains relatively constant or changes very little when the hat is worn.

[0123] For example, for narrow heads, because the hat cannot fit the narrow shape of the head, it may apply hard edges / greater pressure to the wearer's forehead (see [link to article]). Figure 7A and Figure 7B (Identified as HE). For wide heads (also shown in...) Figure 7A and Figure 7B The outer edge of the arc defining the transition area between the visor and crown provides a hard edge / greater pressure (marked HE) along the opposite side surface of the wearer's forehead (e.g., two pressure points on either side of the forehead). Hard edge contact points along some wearers' foreheads can cause abrasions, chafing, discomfort, and even (in some cases) headaches.

[0124] In contrast, the article described and Figure 1A The molded, one-piece hat depicted is capable of significant bending (at least in part due to the continuous layers of fabric and foam, and the obtuse transition angle α defined in the transition area between the visor and the crown), wherein the transition area between the visor and the crown (as...) Figure 8B The curvature or radian angle of the arc (as shown in TR in the figure) Figure 8AThe curve 810 shown (where the arc is on the same plane as the visor) will vary slightly when the crown of the hat is stretched to accommodate wearers with different head sizes / shapes. Specifically, the arc angle defining the transition area between the visor and the hat can vary by at least approximately 5°, or at least approximately 10°, or at least approximately 15°, or at least approximately 20° or greater (e.g., ...). Figure 6 The varying profiles of the front side of the crown 110 are shown in C1 and C2. This results in a minimal or reduced pressure point or hard edge on the wearer's forehead along this arc angle (see...). Figure 8B For different head sizes / shapes, the transition area (TR) between the visor and crown has no hard edges or pressure points because the hat applies a relatively gentle and constant force at the visor / crown transition point on the part of the visor that faces and engages with the wearer's forehead, due to the deformation and bending of the crown and / or visor to conform to the wearer's head shape. In particular, due to the characteristics of the molded one-piece hat, the amount of pressure applied to the wearer's forehead can be reduced by at least 50% compared to conventional hats. Furthermore, as mentioned above, any seams, stitches, and / or folds at the transition between the visor and crown are eliminated, minimizing any friction or hard contact with the wearer's forehead.

[0125] Therefore, the molded one-piece cap described herein accommodates a variety of head sizes without sacrificing comfort. The continuous fabric and foam layers, along with the completely seamless construction at the transition area between the visor and crown, coupled with the obtuse transition angle provided at the transition area, facilitate the cap's flexibility to accommodate different head sizes. This results in a variation in the curvature or arc angle defined along the plane of the visor at the transition between the visor and the cap. This allows for a comfortable fit regardless of head size / shape, with minimal or no pressure points on the wearer's forehead.

[0126] Although Figure 1- Figure 6 The illustrated headwear and its method of formation include a hat with a complete crown and visor. However, it should be noted that other embodiments of the headwear can also be formed, including portions of the headwear, including a visor and (partial or complete) crown portion, formed from a single seamless and integral component, with fabric and intermediate (e.g., foam and / or other) layers extending substantially the entire length of the visor and crown portion. For each embodiment of the headwear, the visor and crown portion are molded as a single, one-piece component with multiple layers that extend continuously along the visor to the crown portion and define transition areas therebetween, wherein the construction and configuration of the visor and crown portion are designed to provide a [missing information - likely a specific feature or feature]. Figure 1A Hats offer the same or similar benefits and effects in transition areas, namely, fitting snugly and providing comfort when wearing headwear, reducing or eliminating hard edges / pressure points on the wearer's forehead.

[0127] refer to Figure 9 In an example embodiment, hat 900 includes a one-piece molded component comprising a crown 110 and a visor 120, having a similar construction and forming layers to those previously described and depicted in Figures 1-2, and these layers extend continuously from the front end of the hat to the rear end. However, hat 900 differs slightly from hat 100 in that the thickness of the intermediate layer 910 (e.g., a foam layer) varies along its length as it extends from the front end of hat 900 (at the visor 120) to the rear end of hat 900 (at the rear end of crown 110). Specifically, the intermediate layer 910 exhibits a thickness transition region (identified by arrow 920) along a portion of crown 110, located between the transition region between visor 120 and crown 110 and a position before reaching the highest point or apex of crown (e.g., before the location where a molded button may be positioned). Figure 9 The embodiments also do not include any molded buttons or molded grooves that mimic seams. However, these may also be provided as optional features of the hat 900.

[0128] The thickness of the intermediate layer 910 decreases at the thickness transition region 920, such that the thickness of the first portion 910A of layer 910 (extending from the front end of the cap 900 to the transition region 920) is greater than the thickness of the second portion 910B of layer 910 (extending from the transition region 920 to the rear end of the cap 900). The thickness of the first portion 910A may be at least 25%, or at least 30%, or at least 40%, or at least 50% or more, or even at least 75% greater than the thickness of the second portion 910B. This variation in the thickness of the intermediate layer 910 may be intended, for example, to ensure the structural integrity of the visor and the transition region between the visor and the crown, while reducing the overall thickness of the crown covering the main or significant portion of the wearer's head (e.g., covering more than 50% of the wearer's head area). This can enhance heat exchange / airflow between the wearer's head and the surrounding environment, in addition to other heat exchange (e.g., cooling) characteristics already present in headwear.

[0129] exist Figure 10A and Figure 10B In another embodiment shown, the hat-shaped headwear is constructed by combining two molded parts and according to... Figure 11The method shown in the flowchart is used to form the hat 1000. The hat 1000 includes a first portion 1010 and a second portion 1020. The first portion 1010 includes a front portion of a visor 120 and a crown 110, and the second portion 1020 includes a rear portion of the crown 110. The front portion includes multiple layers 220, 210, 230, 310, and 320, which are identical or substantially identical in material construction, alignment along the hat portion, and orientation to the layers forming the hat 100. However, it should be noted that the upper fabric layer 220, the lower fabric layer 230, and the middle layer 210 are shortened and do not substantially extend the entire length of the hat (from the front to the back). Conversely, each of these layers 220, 230, 210 extends the entire length of the first portion 1010, which extends from the front end of the cap 1000, the entire length of the visor 120, and along the transition area between the visor 120 and the crown 110 to the highest point or apex of the crown 110 or near it, and to the molded button 115 or near it. The molded button 115 also corresponds to Figure 1- Figure 6 The embodiment is formed by molding in the same manner, and preferably as part of the first portion 1010. Thus, the first portion 1010 is formed by molding a series of generally planar layers that, after molding, form the shape of the visor and crown of the first portion.

[0130] The second part 1020 may include a single layer 1025 of material. This single layer 1025 may include a fabric or textile layer. Alternatively, layer 1025 may include a laminated material or other suitable layer. Figure 10A and Figure 10B In some embodiments, layer 1025 includes a mesh material layer, i.e., a material layer comprising mesh openings or openings of suitable mesh size to promote greater breathability and airflow through the material layer. The mesh material layer may initially have a generally planar construction, wherein the molding process causes layer 1025 to form the curved crown construction of the second portion 1020. Depending on whether it is desired to impart and / or enhance the stiffness of the mesh material layer 1025 after molding it into the crown shape of the second portion 1020, molten and / or non-molten yarns may also be provided to form the mesh material layer 1025.

[0131] The hat 1000 can be formed in a single molding process, wherein two parts, namely a first part 1010 and a second part 1020, are molded and assembled together. These two parts can be molded separately and then assembled (e.g., by sewing, gluing, using seam tape to secure the two parts together, etc.). Alternatively, the two parts can be molded and assembled together in the same molding process. Furthermore, it can be assembled in accordance with Figure 1- Figure 6In a similar manner to the embodiment, the hat 1000 is provided with an edging material 250, which encapsulates the periphery of the first part 1010 and bonds the layers of the first part 1010 together, and further extends continuously around the periphery of the second part 1020 between the two parts 1010 and 1020, so as to further secure them together after the two parts are molded and assembled.

[0132] refer to Figure 11 An example embodiment of the process for forming the cap 1000 will now be described. The generally planar layers used to form the first portion 1010 are initially aligned with Figure 1- Figure 6 A similar construction to the hat shown is provided, the difference being that, as previously described, the lengths of layers 210, 220, and 230 are shortened. Next, these layers are placed or stacked in a suitable order between the upper shell portion and the second shell portion of the mold (step 1120) (e.g., in a manner similar to...). Figure 4A (As shown in the configuration). The upper housing portion and the second housing portion are forced or pressed against each other (step 1130), and the layers are pressed together via the opposing molded surfaces of the housing portions (similar to...). Figure 4D (As shown).

[0133] A generally planar mesh material layer for forming the second part 1020 is placed inside a mold (step 1140), the mold having a... Figure 4A The upper and second housing portions are configured similarly to those shown. These housing portions may also be identical to the housing portions used to form the first portion 1010. In such an embodiment, a first section including the front end of the mold is used to form the first portion of the cap, while a second section including the rear end of the mold is used to form the second portion of the cap. The housing portions of the mold may include markings or identifiers to facilitate alignment of the layers of the first portion of the cap within the mold, and alignment of the mesh material layers used to form the second portion of the cap within the mold. The housing portions, in which the mesh material layers are placed, are pressed together under suitable temperature and pressure conditions (step 1150) to shape the mesh material layers into the shape of the second portion 1020 of the cap 1000.

[0134] The first molded portion 1010 and the second molded portion 1020 are combined together (step 1160) to form Figure 10A and Figure 10B The cap 1000. As previously described, the first and second parts can be combined and secured together by sewing, seam tape, welding and / or any other suitable process. Furthermore, when the first and second parts are aligned with each other, binding material 250 can be provided and secured along their peripheral edge portions (e.g., by sewing, welding and / or other forms of adhesive) to further bond the two molded parts together.

[0135] As mentioned earlier, in Figure 11 In an alternative to the process described in the flowchart, the first and second parts of the hat can be molded in the same molding process or simultaneously. For example, a series of generally planar layers forming the first part 1010 can be placed in the mold and aligned at forward offset positions of the upper and second shell parts, while a generally planar mesh material layer forming the second part 1020 can be placed in the mold and aligned at backward offset positions of the upper and second shell parts. The mesh material layer 1025 can slightly overlap with adjacent edge portions of layers 220, 210, 230 to bond or fuse them together during molding. Alternatively, in addition to any slight edge overlap, one or more seam tape portions can be provided to bridge the adjacent edge portions of the mesh material layer 1025 with those of layers 220, 210, 230 as a material to bond these layers together. This improved process can reduce the number of steps in the manufacturing process of the dual-mold hat 1000.

[0136] refer to Figure 12A , Figure 12B and Figure 12C Further embodiments of a headwear item are described, including a one-piece molded portion extending between a visor and a crown portion of the headwear item. In this embodiment, the headwear item is formed as a sun visor 1200. Specifically, the sun visor 1200 includes a visor 120, which, as shown in Figure 1- Figure 6 The visor 120 of the hat 100 shown is substantially the same. The crown portion 1210 of the sun hat 1200 is also similar to the crown 110 of the hat 100. However, the crown portion 1210 is shortened, making it open and not covering the top portion or crown of the wearer's head. Although not shown, the material layers forming the sun hat 1200 can be similar to the material layers forming the hat 100, for example, as... Figure 3A As shown, layers 310 and 320 of the sun hat 1200 have the same... Figure 3A The layers shown are of the same size and shape. Layers 210, 220, and 230 of the sun hat 1200 are similar to the middle (foam) layer, upper fabric layer, and lower fabric layer of the hat 100, except that the sun hat 1200 will have cutouts or openings in each of these layers (since the crown portion of the sun hat extends only upwards from the visor portion, it is open when worn to expose the top or apex of the wearer's head). The crown portion 1210 extends sufficiently from the transition area between the crown portion 1210 and the visor 120 to achieve the same or similar effect as depicted in the hat 100, namely, to contour around the wearer's forehead and reduce or eliminate pressure points.

[0137] The sun hat 1200 includes multiple linear grooves or channels 1215 ( Figure 12CThese grooves or channels are formed along the surface of the lower fabric layer 230 at the crown portion 1210, which aligns with and faces the wearer's forehead when the sun visor is worn. Channels 1215 partially extend into the lower fabric layer 230 and can be formed during molding in a manner similar to molding grooves 125 (i.e., via protrusions or ribs provided at appropriate locations along the second shell portion of the mold). Channels 1215 extend vertically along the crown portion 1210 and facilitate airflow at a location between the wearer's forehead and the surrounding environment, thereby enhancing the cooling properties of the sun visor 1200 during use. Such grooves or channels can also be provided in similar locations in other headwear embodiments (e.g., hat 100) to provide airflow channels for the headwear when worn.

[0138] Another embodiment of head-wearing items is Figure 13A and Figure 13B The hat 1300 is depicted in the form of a first part 1305, which is similar to... Figure 12A and Figure 12B The sun hat 1200 is further formed by the same or similar molding process as that used for hat 100 and sun hat 1200. The second portion 1320 of hat 1300 is formed from molded parts or molded segments, which are combined with the first portion 1305 to form the hat. Referring now... Figure 14 The flowchart describes a method for forming a headwear or cap 1300. Layers of material (step 1410) are provided to form a generally planar shape for the first portion 1305. These material layers have suitable dimensions and shapes and include a sweatband layer 320, a lower fabric layer 230, a reinforcing plate 310, a middle (foam) layer 210, and an upper fabric layer 220. Specifically, the dimensions of the layers in the first portion 1305 are determined in a manner similar to those used to form the layers of the sun visor 1200, wherein each layer 220, 210, 230 extends continuously from the visor 120, bypasses the transition area between the visor and the crown, and reaches the crown portion 1310, the dimensions of which are set to align with the wearer's forehead when the cap 1300 is used. The layers are stacked sequentially with appropriate alignment between themselves and with the mold housing portion (step 1420), for example, in a manner similar to the stacking of the layers of the sun visor 1200 in the same or similar mold. The shell portion of the mold is pressed together under suitable / set temperature and pressure conditions (step 1430) (e.g., conditions similar to those described earlier in this document when forming hat 100) to mold or form the first portion 1305. Thus, without any further processing, the first portion 1305 has a similar construction to the sun hat 1200.

[0139] Multiple material components or pieces are provided (step 1440) to form the second portion 1320 of the cap 1300. These components include a first side member 1322, a second side member 1324, a first intermediate member 1326, and a second intermediate member 1328. These components have preformed shapes, which are formed via one or more separate molding processes and / or any other suitable process. The shapes of these components are combined by orienting them to each other in a suitable alignment to define a dome-shaped structure that covers and engages with the first portion 1305, thereby forming the cap 1300. Figure 13B As shown, the first and second side members 1322, 1324 define opposite side sections of the second portion 1320, while the first and second intermediate members 1326, 1328 together define the intermediate section of the second portion 1320. Each member has a curved structure suitable for its positioning, such that when these members are assembled, a dome-shaped second portion 1320 is formed.

[0140] The components 1322, 1324, 1326, and 1328 of the second part 1320 are combined with the first part 1305 (step 1450) to close the crown of the hat 1300, wherein each component can be secured to another component and the upper open edge of the first component 1305 in any suitable manner (e.g., via stitching, sealing strips at component / component and / or component / first part interfaces, etc.). Thus, the hat 1300 is formed by molding the first part (including the visor and the crown portion that at least partially covers the wearer's forehead) and then assembling the components to form the dome-shaped second part secured to the first part. It should be noted that any suitable number of components can be combined to form the second part, which is further combined with the molded first part to form the hat. For example, the second part may include one component, two components, three components, or any suitable number of components.

[0141] Therefore, the headwear described herein is formed to include laminated textiles or laminated fabrics in the form of a single, one-piece molded component or sheet. The headwear may also include a combination of two molded components or sheets fixed to each other, or a single molded component or sheet fixed to another sheet formed in any way (molding or otherwise). At least one molded portion of the headwear may be formed as a single, one-piece molded portion comprising a visor and at least a portion of the crown oriented to align with the wearer's forehead, wherein two or more layers (e.g., one or more fabric layers and an intermediate layer, such as a foam layer) extend continuously between the visor and at least a portion of the crown.

[0142] The fabric laminate or one-piece molded component forming the headwear article comprises multiple layers and may include any selected number of layers, wherein different fabric laminates comprising different types and / or numbers of layers may be provided at different locations of the headwear article. For example, certain locations of the headwear article may include one or more internal structural supports, while other locations may not, thereby altering the structural configuration of the fabric laminate at different locations of the headwear article.

[0143] At least one intermediate layer, extending continuously between the visor and crown and substantially extending the length of the headwear, may include a foam layer. Alternatively, at least one intermediate layer, extending continuously between the visor and crown and substantially extending the length of the headwear, may include a fabric layer. Upper and lower fabric layers forming the exposed surface of the headwear also extend continuously between the visor and crown and substantially extend the length of the headwear. This construction provides a suitable transition angle in the transition area between the visor and crown and further facilitates a curvature and fit to the shape of the wearer's head (including the forehead) to minimize or eliminate hard edges or pressure points that might otherwise be present at the point of contact between the headwear and the wearer's forehead in the transition area, depending on the specific size or shape of the wearer's head.

[0144] The fabric layers forming parts of the headwear (e.g., upper and lower fabric layers and / or one or more intermediate fabric layers) may be knitted, woven, embroidered and / or nonwoven fabric layers, and may optionally include molten and / or nonmolten yarns as described herein to increase the stiffness of the headwear and / or enhance its structural integrity and its “memory” or shape retention (i.e., the ability to recover and maintain a molded shape even after the headwear has been deformed by compression and / or bending forces).

[0145] The headwear embodiments described herein can be further configured to have heat transfer or thermal insulation enhancement properties on any one or more layers of the headwear. For example, as described above, cooling and / or thermal insulation properties can be imparted to the lower fabric layer (and / or any other layer of the headwear) by providing fibers and / or yarns of different shapes and / or additives to the fabric layer, these fibers and / or yarns contributing to altering one or more thermal properties of the fabric layer based on temperature changes applied to the fabric layer. Other features, such as grooves or channels along a surface portion of the headwear (e.g., the lower fabric layer), and perforations through portions of the headwear, can also be provided to selective areas of the headwear via a molding process to enhance airflow between the wearer's head and the surrounding environment during use of the headwear.

[0146] The molding process used to form at least a portion of a headwear item (which is a single, seamless component) minimizes or eliminates the use of stitches or other seams that can create hard or rough surfaces or edges, causing discomfort to the wearer. Furthermore, certain aesthetic features, such as buttons or seam lines along parts of the headwear item, can be artificially created through the molding process in the form of molded buttons and molded grooves mimicking seam lines. Through-holes or vents, as well as other features, can also be formed in the headwear item via the molding process.

[0147] In summary, the exemplary embodiments of hats or other headwear items described herein include the features pointed out herein as well as the features set forth below. It should be noted that the features set forth below can be provided to hats or headwear items in any number of different combinations.

[0148] In an example embodiment, a headwear includes a crown portion sized to cover a portion of a wearer's forehead when the headwear is worn; and a visor extending laterally from the crown portion. The crown portion and visor are formed from a single, one-piece molded body including an upper fabric layer, a lower fabric layer, and an intermediate layer disposed between the upper and lower fabric layers, each of the upper, lower, and intermediate layers extending continuously between the crown portion and the visor. Furthermore, a transition angle is defined at the transition between the visor and the crown portion, wherein the transition angle is an obtuse angle. The transition angle may be at least about 100°, at least about 110°, or at least about 120°, or 130° or even greater.

[0149] An arc may be defined within the plane of the visor at the transition between the visor and the crown portion, and the curvature of the arc may respond to stretching of the visor and / or the crown portion to accommodate different head sizes of the wearer. The curvature of the arc may be configured to vary by at least about 5°, or at least about 10°, or at least about 15°, or at least about 20° or greater.

[0150] At least one of the upper fabric layer, lower fabric layer, and intermediate layer may include a material having an elongation of about 50% to about 75% when aligned along the length of the head-wearing article. Furthermore, the material of at least one of the upper fabric layer, lower fabric layer, and intermediate layer may also have an elongation of about 90% to about 120% when aligned in a direction transverse to the length of the head-wearing article. Further, the material of at least one of the upper fabric layer, lower fabric layer, and intermediate layer may have a recovery rate greater than about 80% when aligned along the length direction and / or in a direction transverse to the length direction.

[0151] The intermediate layer may include a foam layer.

[0152] At least one fabric layer may extend continuously between the crown portion and the visor, and includes a molten yarn with a glass transition temperature not greater than about 150 °C, the molten yarn being fused with other yarns within at least one fabric layer that intersect with the molten yarn.

[0153] The exposed surface of one or both of the upper and lower fabric layers may include one or more raised protrusions and / or one or more grooves, which are disposed at one or more locations along the exposed surface and are formed during the molding process of the headwear. The exposed surface of the upper fabric layer may include protrusions along the crown portion, which are shaped like buttons. The exposed surface of the upper fabric layer may include multiple grooves along the visor, which are shaped like stitches.

[0154] The lower fabric layer may include one or more components that alter the thermal properties of the lower fabric layer based on temperature changes applied to it. The lower fabric layer may have a thermal property of at least 0.1 W / m². 2 Qmax rating.

[0155] The lower fabric layer may include particles selected from titanium dioxide, jade, mica, graphene, and any combination thereof.

[0156] The lower fabric layer may include polyester filaments embedded with mica, wherein the polyester filaments have a wavy cross section.

[0157] Headwear items should have a breathability of at least approximately 300 CFM.

[0158] In other example embodiments, a headwear includes a crown portion sized to cover a portion of a wearer's forehead when the headwear is worn; and a visor extending laterally from the crown. The crown portion and the visor are formed from a single, one-piece molded body including an upper fabric layer, a lower fabric layer, and an intermediate layer disposed between the upper and lower fabric layers, each of the upper, lower, and intermediate layers extending continuously between the crown and the visor. The visor also includes a reinforcing member extending within the visor between the upper and lower fabric layers.

[0159] The reinforcing member can be located between the intermediate layer and the lower fabric layer.

[0160] The intermediate layer may include foam material.

[0161] The reinforcing member may have a stiffness test value greater than that of each of the upper, lower, and middle fabric layers. Furthermore, the reinforcing member may extend within the visor to terminate at or before the transition area between the visor and the crown. Alternatively, the reinforcing member may extend within the visor, along the transition area between the visor and the crown, and beyond the transition area between the visor and the crown.

[0162] The visor and / or crown may include one or more perforations that extend through the visor and / or crown.

[0163] Binding material can be provided along the outer perimeter edges of the upper, middle, and lower fabric layers. The binding material can be folded onto the outer perimeter edges.

[0164] A sweatband layer can be provided that extends to cover the exposed portion of the underlying fabric layer. The sweatband layer can extend along the transition area between the visor and the crown to cover the exposed portion of the underlying fabric layer.

[0165] A transition angle may be defined at the transition between the visor and the crown portion, and the transition angle may be an obtuse angle. The transition angle may be at least approximately 100°, at least approximately 110°, or at least approximately 120°, or 130° or even greater.

[0166] An arc may be defined within the plane of the visor at the transition between the visor and the crown portion, and the curvature of this arc may respond to stretching of the visor and / or crown portion to accommodate different head sizes of the wearer. The curvature of the arc may be configured to vary by at least about 5°, or at least about 10°, or at least about 15°, or at least about 20° or greater.

[0167] The exposed surface of one or both of the upper and lower fabric layers may include one or more molded protrusions and / or one or more molded recesses, which are disposed at one or more locations along the exposed surface. For example, a molded button may be located along the crown portion, wherein the molded button is defined by a corresponding convex portion of each of the upper, middle, and lower fabric layers at the exposed outer and exposed inner surface portions of the crown. Furthermore, the exposed inner surface portion of the lower fabric layer may have a concave shape at the molded button.

[0168] The lower fabric layer may include one or more components that alter the thermal properties of the lower fabric layer based on temperature changes applied to it.

[0169] In a further example embodiment, a headwear includes a crown portion sized to cover a portion of the wearer's forehead when the wearer wears the headwear; a visor extending laterally from the crown; and a molded button having a raised three-dimensional shape defined on the exposed outer surface portion of the crown.

[0170] Molded buttons can be positioned at the apex of the crown. Molded buttons can also have a hemispherical three-dimensional shape.

[0171] The crown may include a recess on the exposed inner surface portion of the crown, the recess corresponding to a raised three-dimensional shape defined on the exposed outer surface portion of the crown.

[0172] The crown portion and the visor can be formed from a single one-piece molded body, which includes an upper fabric layer for the exposed outer surface portion of the crown, a lower fabric layer for the exposed inner surface portion of the crown, and an intermediate layer disposed between the upper and lower fabric layers, and each of the upper, lower, and intermediate fabric layers can extend continuously between the crown and the visor.

[0173] The molded button may be further defined by corresponding convex portions of each of the upper, middle, and lower fabric layers at the exposed outer and inner surfaces of the crown. Furthermore, the exposed inner surface of the lower fabric layer may have a concave shape at the molded button.

[0174] Multiple molded grooves can extend along the exposed outer surface of the upper fabric layer at the visor.

[0175] Multiple molded ridges can extend along the further exposed outer surface portion of the upper fabric layer at the crown.

[0176] In an additional embodiment, a headwear includes a crown portion sized to cover a portion of a wearer's forehead when the headwear is worn; and a visor extending laterally from the crown, wherein the crown portion and the visor are formed from a single one-piece molded body including an upper fabric layer, a lower fabric layer, and an intermediate layer disposed between the upper and lower fabric layers, and each of the upper, lower, and intermediate fabric layers extends continuously between the crown and the visor. At least one molded feature is formed as a recess and / or protrusion along the exposed surface of the visor and / or crown.

[0177] At least one molded feature may include a molded button located along the crown. The molded button may have a hemispherical shape defined by a convex portion of the upper fabric layer. Each of the middle and lower fabric layers may include a convex portion corresponding to the convex portion of the upper fabric layer. The lower fabric layer may include an exposed concave surface corresponding to the convex portion of the upper fabric layer.

[0178] At least one molding feature may include a plurality of molding grooves formed within the exposed surface portion of the upper fabric layer at the visor. Each molding groove may be U-shaped. The molding grooves may be continuously aligned in a nested pattern.

[0179] At least one molding feature may include multiple molded ridges formed along the exposed surface portion of the upper fabric layer at the crown.

[0180] In a further example embodiment, a headwear includes a molded crown portion and a molded visor portion, the visor portion including a textile layer, a foam layer, and a structural element having a radius of curvature facing the wearer's head. The structural element is disposed between the foam layer and the textile layer, and the structural element is dynamic, causing the radius of curvature to change under load to adapt to the curvature of the wearer's forehead.

[0181] The visor portion can transition to the crown portion in the transition area, and the radius of curvature is located outside the transition area.

[0182] The visor portion may include a textile layer and a foam layer, and the crown portion and the visor portion may form a single-piece molded body.

[0183] The crown portion can be an open crown, including an opening near the apex of the crown. Alternatively, the crown portion can be a closed crown.

[0184] In an embodiment of a headwear item, the textile layer is a first textile layer, the foam layer is a first foam layer, and the visor portion includes the first textile layer, the first foam layer, a structural element, a second textile layer, and a second foam layer. The structural element may be an elastic, non-foamed sheet capable of in-plane and out-of-plane bending. Furthermore, the structural element may include a series of openings. Upon compression, the foam may extend through one or more openings of the structural element.

[0185] Structural components can be injection-molded plastic sheets.

[0186] Headwear may also include textures molded into the visor and / or the crown.

[0187] In a further example embodiment, a method of forming a headwear article includes: placing a plurality of layers in a stacked orientation within a mold, wherein the plurality of layers include a lower fabric layer, a middle layer, and an upper fabric layer; and pressing the plurality of layers together within the mold to form a one-piece molded member including the layers, the one-piece molded member having a three-dimensional shape. The one-piece molded member defines a crown portion sized to cover a portion of the wearer's forehead when the wearer wears the headwear article; and a visor extending laterally from the crown portion, with each of the plurality of layers extending between the visor and the crown portion.

[0188] Multiple layers can be arranged in a stacked orientation such that at least one of the upper fabric layer, the lower fabric layer, and the middle layer has an elongation of about 50% to about 75% in the mold direction corresponding to the length direction of the headwear, which extends from the visor to the crown portion.

[0189] Multiple layers may also be arranged in a stacked orientation such that at least one of the upper fabric layer, the lower fabric layer, and the middle layer has an elongation of about 90% to about 120% in the mold direction corresponding to the transverse direction of the length of the head-wearing item.

[0190] When at least one of the upper fabric layer, lower fabric layer and middle layer is aligned along the length of the headwear and / or in a direction transverse to the length of the headwear, it can have a recovery rate of more than about 80%.

[0191] The intermediate layer may include a reinforcing plate comprising a material with a stiffness greater than that of each of the upper and lower fabric layers. After multiple layers are laminated together in a mold, the reinforcing plate may extend within a single-piece molded component to extend continuously from the visor to the crown portion and bypass the transition area defined between the visor and the crown portion.

[0192] The reinforcing plate may include multiple through holes penetrating the reinforcing plate.

[0193] Placing multiple layers in a stacked orientation within a mold may also include placing a foam layer between an upper fabric layer and a reinforcing plate or between a lower fabric layer and a reinforcing plate. Pressing multiple layers together within a mold to form a single-piece component may include forcing portions of the foam layer against the reinforcing plate such that portions of the foam layer extend into and / or through through-holes in the reinforcing plate.

[0194] The intermediate layer may include a foam layer. Each of the upper fabric layer, lower fabric layer, and foam layer may extend substantially the entire length of the single-piece component.

[0195] Each of the multiple layers can have a planar shape when placed in a stacked orientation within the mold.

[0196] The crown portion can be closed to define a dome-shaped component that covers the wearer's head.

[0197] Alternatively, the crown portion may be open to cover only a portion of the wearer's head, and the method may further include combining the crown portion of the one-piece component with a second crown portion to form a closed crown that covers the wearer's head. The second crown portion may include a mesh material. The second crown portion may alternatively include multiple segments combined to form the second crown portion.

[0198] Although the invention has been described in detail with reference to specific embodiments, it will be clear to those skilled in the art that various changes and modifications can be made without departing from its spirit and scope.

[0199] Therefore, it is intended that this invention cover modifications and variations thereof, provided they fall within the scope of the appended claims and their equivalents. It should be understood that terms such as “top,” “bottom,” “front,” “rear,” “side,” “height,” “length,” “width,” “upper,” “lower,” “inner,” and “outer” that may be used herein describe reference points only and do not limit the invention to any particular orientation or construction.

Claims

1. A head-mounted item, comprising: The crown portion is sized to cover a portion of the wearer's forehead when the wearer wears the headwear; as well as A visor that extends laterally from the crown; in: The crown portion and the visor are formed from a single one-piece molded body, the single one-piece molded body including an upper fabric layer, a lower fabric layer, and an intermediate layer disposed between the upper fabric layer and the lower fabric layer, and each of the upper fabric layer, the lower fabric layer, and the intermediate layer extends continuously between the crown and the visor; and The visor also includes a reinforcing member that extends within the visor between the upper and lower fabric layers.

2. The head-wearing article according to claim 1, wherein, The reinforcing member is located between the intermediate layer and the lower fabric layer.

3. The head-wearing article according to any one of the preceding claims, wherein, The intermediate layer comprises a foam material.

4. The head-wearing article according to any one of the preceding claims, wherein, The reinforcing member has a hardness tester value that is greater than that of each of the upper fabric layer, the lower fabric layer, and the intermediate layer.

5. The head-wearing article according to any one of the preceding claims, wherein, The reinforcing member extends within the visor and terminates at or before the transition area between the visor and the crown.

6. The head-wearing article according to any one of claims 1-4, wherein, The reinforcing member extends within the visor along the transition region between the visor and the crown, and beyond the transition region.

7. The head-wearing article according to any of the preceding claims, wherein, The visor and / or the crown includes one or more perforations therethrough.

8. The headwear article according to any of the preceding claims further includes a binding material provided along the outer peripheral edge portions of the upper fabric layer, the middle layer, and the lower fabric layer.

9. The head-wearing article according to claim 8, wherein, The binding material is folded onto the outer peripheral edge portion.

10. The headwear article according to any of the preceding claims further includes a sweatband layer that extends to cover the exposed portion of the underlying fabric layer.

11. The head-wearing article according to claim 10, wherein, The sweatband layer extends along the transition area between the visor and the crown, covering the exposed portion of the lower fabric layer.

12. The head-wearing article according to any of the preceding claims, wherein, A transition angle is defined at the transition between the visor and the crown portion, and the transition angle is an obtuse angle.

13. The head-wearing article according to claim 12, wherein, The transition angle is at least about 100°, at least about 110°, or at least about 120°, or 130° or even greater.

14. The head-wearing article according to claim 12, wherein, An arc is defined in the plane of the visor at the transition between the visor and the crown portion, and the curvature of the arc varies in response to the stretching of the visor and / or the crown portion to accommodate different sizes of the wearer's head.

15. The head-wearing article according to claim 14, wherein, The curvature of the arc is configured to vary by at least about 5°, or at least about 10°, or at least about 15°, or at least about 20° or greater.

16. The head-wearing article according to any of the preceding claims, wherein, The exposed surfaces of one or both of the upper and lower fabric layers include one or more molded protrusions and / or one or more molded grooves, the one or more molded protrusions and / or one or more molded grooves being disposed at one or more locations along the exposed surface.

17. The headwear article according to any of the preceding claims further includes a molded button positioned along the crown portion, wherein the molded button is defined by corresponding convex portions of each of the upper fabric layer, the intermediate layer, and the lower fabric layer at the exposed outer and exposed inner surface portions of the crown.

18. The head-wearing article according to claim 17, wherein, The exposed inner surface portion of the lower fabric layer has a concave shape at the molded button.

19. The head-wearing article according to any of the preceding claims, wherein, The lower fabric layer includes one or more components that alter the thermal properties of the lower fabric layer based on temperature changes applied to it.

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