Flexible Fit Cap with Memory Foam Headband

Abstract

A cap configured to be worn on a wearer's head includes a crown characterized by a substantially elliptical opening that has a circumference and one or more radii normal to the circumference, a bill connected to the crown, and a substantially elliptical sweatband connected to the crown. The sweatband has a front portion that is compliant in a radial direction and a back portion that is flexible in an axial direction. The front portion includes a front contact layer configured to be in contact with the wearer's head, a concealed backing layer adjacent to the crown, and a compliant layer between the front contact layer and the concealed backing layer. The compliant layer is compliant in the radial direction. The back portion has a rear contact layer configured to be in contact with the wearer's head and a concealed support layer.

It is claimed: 
     
         1 . A cap configured to be worn on a wearer's head, the cap comprising:
 a crown, wherein the crown is characterized by a substantially elliptical opening that has a circumference and one or more radii normal to the circumference;   a bill connected to the crown; and   a substantially elliptical sweatband connected to the crown, wherein the sweatband comprises:
 a front portion that is compliant in a radial direction, wherein the front portion comprises:
 a front contact layer configured to be in contact with the wearer's head; 
 a concealed backing layer adjacent to the crown; and 
 a compliant layer between the front contact layer and the concealed backing layer, wherein the compliant layer is compliant in the radial direction; and 
 
 a back portion that is flexible in an axial direction, wherein the back portion comprises:
 a rear contact layer configured to be in contact with the wearer's head; and 
 a concealed support layer. 
 
   
     
     
         2 . The cap of  claim 1 , wherein the concealed support layer of the back portion of the sweatband is construed from an elastic material. 
     
     
         3 . The cap of  claim 2 , wherein the back portion of the sweatband is flexible in biaxial directions. 
     
     
         4 . The cap of  claim 1 , wherein the compliant layer comprises low-resilience polyurethane foam. 
     
     
         5 . The cap of  claim 3 , wherein the compliant layer is configured to adapt to heat produced by the wearer's head. 
     
     
         6 . The cap of  claim 5 , wherein the compliant layer is configured to soften and mold to the wearer's head in response to heat produced by the wearer's head. 
     
     
         7 . The cap of  claim 1 , wherein the crown comprises a plurality of gores, wherein one or more of the plurality of gores are manufactured from fabric that has lateral and longitudinal elasticity. 
     
     
         8 . The cap of  claim 7 , wherein the rear contact layer of the back portion of the sweatband is manufactured from fabric that has lateral and longitudinal elasticity. 
     
     
         9 . The cap of  claim 8 , wherein the rear contact layer of the back portion of the sweatband is manufactured from the same fabric that is used to manufacture the one or more of the plurality of gores. 
     
     
         10 . The cap of  claim 9 , wherein the front contact layer of the front portion of the sweatband is manufactured from the same fabric that is used to manufacture the one or more of the plurality of gores. 
     
     
         11 . The cap of  claim 1 , wherein the front portion includes diamond quilted stitching through the first contact layer, compliant layer and backing layer. 
     
     
         12 . The cap of  claim 1 , wherein the front portion and back portion are connected by a seam cover. 
     
     
         13 . A cap configured to be worn on a wearer's head, the cap comprising:
 a crown, wherein the crown is characterized by a substantially elliptical opening that has a circumference and one or more radii normal to the circumference;   a bill connected to the crown; and   a substantially elliptical sweatband connected to the crown, wherein the sweatband comprises:
 a front portion adjacent to the bill, wherein the front portion is compliant in a radial direction; and 
 a back portion connected to the front portion, wherein the back portion is biaxially flexible in a circumferential direction. 
   
     
     
         14 . The cap of  claim 13 , wherein the front portion comprises:
 a front contact layer configured to be in contact with the wearer's head;   a concealed backing layer adjacent to the crown; and   a compliant layer between the front contact layer and the concealed backing layer, wherein the compliant layer is compliant in the radial direction.   
     
     
         15 . The cap of  claim 13 , wherein the back portion comprises:
 a rear contact layer configured to be in contact with the wearer's head; and   a concealed support layer.   
     
     
         16 . The cap of  claim 15 , wherein the concealed support layer of the back portion of the sweatband is construed from an elastic material. 
     
     
         17 . The cap of  claim 13 , wherein the compliant layer comprises low-resilience polyurethane foam. 
     
     
         18 . The cap of  claim 1 , wherein the front portion and back portion are connected by a seam cover. 
     
     
         19 . A cap configured to be worn on a wearer's head, the cap comprising:
 a crown, wherein the crown is characterized by a substantially elliptical opening that has a circumference and one or more radii normal to the circumference; and   a substantially elliptical sweatband connected to the crown, wherein the sweatband comprises:
 a front portion that comprises:
 a front contact layer configured to be in contact with the wearer's head; 
 a concealed backing layer adjacent to the crown; and 
 a compliant layer between the front contact layer and the concealed backing layer, wherein the compliant layer is compliant in a radial direction; and 
 
 a back portion connected to the front portion, wherein the back portion comprises:
 a rear contact layer configured to be in contact with the wearer's head; and 
 a concealed elastic support layer. 
 
   
     
     
         20 . The cap of  claim 19 , wherein the rear contact layer and the concealed elastic support layer are both flexible in biaxial directions.