Abstract: Headwear having a crown portion and a headband attached to and extending around the lower inside edge of the crown portion. The sewing thread used on the headband includes rubber thread and nylon stretch thread sewn together in a chain-like pattern to provide expandability and thereby increase the number of different wearer head sizes that may be accommodated by the headband. With this construction, a wide range of automatic size adjustment is obtained without imposing undue elastic pressure on the wearer.

Abstract: Headwear having a two-ply headband coated with a layer of polyurethane. The headwear includes a crown main body, a visor, and the headband which is preferably connected to the lower peripheral edge of the crown main body. The two-ply headband is created by folding a strip of knitted fabric, coated on one side with polyurethane, so that the polyurethane is inside the folds and then stitching the folds to secure the shape of the headband. The knitted portion of the headband demonstrates good moisture absorbency while the polyurethane layer prevents the conveyance of sweat to the crown main body and any accompanying staining that might otherwise occur. The headband stretches to fit the wearer comfortably without undue pressure during use, while also exhibiting good resilience when removed.

Abstract: A baseball-style cap having a freely transformable visor which includes an upper fabric portion, a lower fabric portion, and a resilient stiffener placed therebetween. The cap further includes a piped fabric portion that is located between the upper and lower fabric portions, adjacent an outer periphery of such upper and lower portions, into which a deformable material is inserted. The deformable material includes a plastic sheath defining a channel, and a metal material lying within the channel and enclosed thereby. The combination of the resilient stiffener and the deformable material allows the visor to be readily bent or folded as well as easily restored to its original configuration. The resulting cap can be produced easily, is attractive in use and can be carried in a pocket without damage to the visor.

Abstract: A baseball-style cap having a pliable visor which includes an upper fabric portion, a lower fabric portion, and a resilient stiffener placed therebetween. The cap further includes a piped fabric portion that is located between the upper and lower fabric portions, adjacent an outer periphery of such upper and lower portions, into which a deformable material is inserted. The combination of the resilient stiffener and the deformable material allows the visor to be readily bent or folded as well as easily restored to its original configuration. The resulting cap can be produced easily, is attractive in use and can be carried in a pocket without damage to the visor.

Abstract: A grooved size adjustment strap for a baseball-style cap having a crown body and a visor. The size adjustment strap, which is attached to the back portion of the lower periphery of the crown, is formed by an inner strap and an outer strap, each strap attached to a respective side of the crown main body along a lower edge thereof. Each of the straps is formed of a reinforcing material such as PVC sheet, with hook or loop material attached thereto, respectively. The outer strap is formed with the PVC sheet faced outwardly and includes a plurality of vertical grooves that facilitate shape formation and retention of the size adjustment device, and also assist in predictable size adjustment.

Abstract: A baseball-style cap having a crown portion made of multiple panels, a visor part which is attached to the front part of the crown portion and a headband attached to and extending around the lower inside edge of the crown portion. The headband is a band of two-ply elastic yarn material woven in a tubular or tunnel shape that contains no polyurethane. With this construction good perspiration absorbency is obtained without imposing undue elastic pressure on the wearer.

Abstract: Headwear having a head-fitting portion and a visor portion, with an extended fabric portion stretching from the top of the head-fitting portion to the front edge of the visor portion to create the appearance of a unitary crown and visor. The resulting headwear, which can include a baseball-style cap and a sun visor, can be produced easily and is attractive in use, enabling decorative portions to transition without interruption from the visor to and across the head-fitting portion.

Abstract: Headwear having a head-fitting portion and a visor portion, with an extended fabric portion stretching from the top of the head-fitting portion to the front edge of the visor portion to create the appearance of a unitary crown and visor. The resulting headwear, which can include a baseball-style cap and a sun visor, can be produced easily and is attractive in use, enabling decorative portions to transition without interruption from the visor to and across the head-fitting portion.

Abstract: A cap with a pattern mold sheet including a crown main body formed by a plurality of panels, and a visor portion that is secured to a forward edge of the crown and which extends outwardly therefrom. In order to give an improved three-dimensional effect to a desired pattern such as logos, symbols, or emblems which a user wants, the pattern mold sheet is used which heightens the three-dimensional effect as compared with the traditional use of embroidery threads. The pattern mold sheet is formed with a three-layer structure including an upper stretchable fabric material or polyurethane, a sponge and a lower fabric material. The pattern mold sheet is formed by heating a sheet with the heater and pressing the mold frame with the shape of the pattern and the size of the sheet a user wants on the heated sheet with a compressor. The level of the pattern can be differently represented on the pattern mold sheet by varying the depth of the inner part of the mold frame, thus heightening the three-dimensional effect.

Abstract: A baseball-style cap having a sweatband woven to form a tubular channel. The cap includes a crown main body, a visor, and the sweatband. The sweatband is connected to the lower peripheral edge of the crown main body. The tubular weaving of the sweatband reduces manufacturing steps as no sewing of two unjoined ends is necessary. In addition, the sweatband is woven of thread having good moisture absorbency such that subsidiary materials for enhancement of perspiration absorption are not required. The resulting sweatband is uniform in appearance, having the same look on both the inner and outer surfaces, upgrading the quality of the sweatband and enhancing aesthetic appeal.

Abstract: A baseball-syle cap having a free-size capability for accommodating wearers having a range of head sizes without a separate sizing mechanism. The cap includes a crown main body which is expandable at least in a peripheral direction, and a headband made of a substantially non-stretchable fabric material. The headband is connected to the lower peripheral edge of the crown main body by a piece of stretchable fabric which is sewn to cover the headband. The lower peripheral edge of the headband is incised or grooved at regular intervals such that a stretching force thereon in the peripheral direction causes the headband to demonstrate teeth appearance.

Abstract: A cap with a pattern mold sheet including a crown main body formed by a plurality of panels, and a visor portion that is secured to a forward edge of the crown and which extends outwardly therefrom. In order to give an improved three-dimensional effect to a desired pattern such as logos, symbols, or emblems which a user wants, the pattern mold sheet is used which heightens the three-dimensional effect as compared with the traditional use of embroidery threads. The pattern mold sheet is formed with a three-layer structure including an upper stretchable fabric material or polyurethane, a sponge and a lower fabric material. The pattern mold sheet is formed by heating a sheet with the heater and pressing the mold frame with the shape of the pattern and the size of the sheet a user wants on the heated sheet with a compressor. The level of the pattern can be differently represented on the pattern mold sheet by varying the depth of the inner part of the mold frame, thus heightening the three-dimensional effect.