Baseball style cap, sun visor cap, and gym wrap device having improved moisture absorption and cooling

Abstract

A baseball style cap having a crown portion, a brim, and a sweatband is provided. The sweatband has a first polyester mesh fabric layer and a moisture activated cooling mesh fabric layer. The first polyester mesh fabric layer has a plurality of holes extending therethrough each having a first opening size. The moisture activated cooling mesh fabric layer is constructed of substantially 55% nylon yarn and substantially 45% polyester yarn. The crown portion has a second polyester mesh fabric layer and a third polyester mesh fabric layer. The second polyester mesh fabric layer has a plurality of holes extending therethrough with the first opening size. The third polyester mesh fabric layer has a plurality of holes extending therein having a second opening size smaller than the first opening size.

1 . An article of headwear, comprising:
 a first polyester mesh fabric layer is configured to contact a head of a user, the first polyester mesh fabric layer includes a first plurality of holes that extend completely therethrough and are configured so that moisture from the head of the user can propagate through the first plurality of holes;   a moisture activated cooling mesh fabric layer is configured to absorb moisture from the head of the user, the moisture activated cooling mesh fabric layer includes nylon and polyester yarns arranged in a capillary-like structure that absorbs moisture from the head of the user and distributes moisture throughout the moisture activated cooling mesh fabric layer; and   a second polyester mesh fabric layer is configured to evaporate moisture from the head of the user to the surrounding atmosphere.   
     
     
         2 . The article of headwear of  claim 1 , wherein each of the first plurality of holes has a first opening size with a diameter in a range of 2.5 mm to 3.5 mm and is configured so that moisture can propagate through the first plurality of holes from the head of the user to the moisture activated cooling mesh fabric layer. 
     
     
         3 . The article of headwear of  claim 1 , wherein each of the first and second polyester mesh fabric layers is comprised of 100% polyester. 
     
     
         4 . The article of headwear of  claim 1 , wherein the moisture activated cooling mesh fabric layer is comprised of substantially 55% nylon yarn and substantially 45% polyester yarn. 
     
     
         5 . The article of headwear of  claim 1 , wherein the moisture activated cooling mesh fabric layer has a surface water absorption that is greater than that of each of the first and second polyester mesh fabric layers. 
     
     
         6 . The article of headwear of  claim 1 , wherein the moisture activated cooling mesh fabric layer has a surface water absorption of 8 ml in a 1 m by 1 m area of the moisture activated cooling mesh fabric layer. 
     
     
         7 . The article of headwear of  claim 1 , wherein the moisture activated cooling mesh fabric layer has a wicking rate in a range of 3.3 mm/s to 4.0 mm/s. 
     
     
         8 . The article of headwear of  claim 1 , wherein the second polyester mesh fabric layer includes an interior side, an exterior side, and a second plurality of holes, each of the second plurality of holes extends partially into the second polyester mesh fabric layer from the exterior side but does not extend completely through to the interior side. 
     
     
         9 . The article of headwear of  claim 8 , wherein each of the second plurality of holes has a second opening size with a diameter in a range of 1.2 mm to 2.0 mm. 
     
     
         10 . The article of headwear of  claim 1 , wherein the second polyester mesh fabric layer includes a second plurality of holes, each of the first plurality of holes has a first opening size and each of the second plurality of holes has a second opening size, each of the second opening sizes is smaller than each of the first opening sizes so that an outer surface area of the second polyester mesh fabric layer is greater than that of the first polyester mesh fabric layer, and the greater outer surface area of the second polyester mesh fabric layer is configured so that moisture from the head of the user can more easily evaporate therefrom. 
     
     
         11 . The article of headwear of  claim 1 , wherein the article of headwear is a baseball style cap and further includes a crown portion, a sweatband coupled to the crown portion, and a brim coupled to the crown portion. 
     
     
         12 . The article of headwear of  claim 11 , wherein the first polyester mesh fabric layer is part of the sweatband and is configured to contact the head of the user, the moisture activated cooling mesh fabric layer is part of the sweatband and is coupled to the first polyester mesh fabric layer, another polyester mesh fabric layer is part of the crown portion and is coupled to the moisture activated cooling mesh fabric layer, and the second polyester mesh fabric layer is part of the crown portion and is coupled to the other polyester mesh fabric layer. 
     
     
         13 . The article of headwear of  claim 11 , wherein the crown portion includes one or more front panel portion(s), one or more side panel portion(s) coupled to the front panel portion(s), and one or more rear panel portion(s) coupled to the side panel portion(s), the front panel portion(s) have a pair of polyester mesh fabric layers whereas the side panel portion(s) and the rear panel portion(s) have a single polyester mesh fabric layer. 
     
     
         14 . The article of headwear of  claim 11 , wherein the crown portion includes one or more front panel portion(s), one or more side panel portion(s) coupled to the front panel portion(s), and one or more rear panel portion(s) coupled to the side panel portion(s), each of the front panel portion(s), the side panel portion(s) and the rear panel portion(s) has a pair of polyester mesh fabric layers. 
     
     
         15 . The article of headwear of  claim 11 , wherein the crown portion includes the second polyester mesh fabric layer, the sweatband includes the first polyester mesh fabric layer and the moisture activated cooling mesh fabric layer, and the brim includes third and fourth polyester mesh fabric layers and a central plastic portion. 
     
     
         16 . The article of headwear of  claim 1 , wherein the article of headwear is a sun visor cap and further includes a sweatband and a brim coupled to the sweatband. 
     
     
         17 . The article of headwear of  claim 16 , wherein the first polyester mesh fabric layer is part of the sweatband and is configured to contact the head of the user, the moisture activated cooling mesh fabric layer is part of the sweatband and is coupled to the first polyester mesh fabric layer, and the second polyester mesh fabric layer is part of the sweatband and is coupled to the moisture activated cooling mesh fabric layer. 
     
     
         18 . The article of headwear of  claim 16 , wherein the sweatband includes the first polyester mesh fabric layer, the moisture activated cooling mesh fabric layer, and the second polyester mesh fabric layer, and the brim includes third and fourth polyester mesh fabric layers and a central plastic portion.