Abstract: A sports cap, having a stretchable pocket on the entire top surface of the visor and preferably worn on the head of a user while exercising, golfing, climbing or fishing, is disclosed. This sports cap has a visor integrated along the lower front edge of a crown into a single body through a sewing process, which a pocket provided on the entire top surface of the visor by sewing a stretchable pocket fabric along the rounded front edge of the visor. An opening is formed on the pocket at a position along the rear edge of the stretchable pocket fabric, with an elastic tape liner integrated along the rear edge of the pocket fabric and sewn to the visor at opposite ends thereof together with the pocket fabric so as to elastically tighten the opening of the pocket. The sports cap allows a user to easily and conveniently store a variety of personal necessities, such as golf tees, ball markers, a cigarette pack, a lighter, a match box, scratch papers, name cards, receipts, or score sheets, in the pocket.

Abstract: A sweatband for headgear is disclosed. The sweatband has a plurality of laminated absorbent non-woven fabric strips. One or more first unabsorbent non-woven fabric strips are interposed between the laminated absorbent non-woven fabric strips. A second unabsorbent non-woven fabric strip is positioned at the back of the laminated absorbent non-woven fabric strips. The fabric strips are bonded together. A plurality of vertical slits are formed along the upper and lower edges of the bonded fabric strips at intervals. According to another embodiment, intervals of the slits may be 6 mm and lengths of the slits may be 5 mm.

Abstract: A device and method of shaping the visors of caps is disclosed. In the device, a visor shaping unit has a movable upper mold and a fixed lower mold. The upper mold, with a coil heater, is outwardly curved into a predetermined curvature at its lower surface and is operated by a hydraulic cylinder. The lower mold is inwardly curved into the same curvature as that of the upper mold at the top surface. The cooling unit has first to third chambers with a plurality of perforated sections being formed on the top wall of each of the chambers. Upper and lower panels are exteriorly attached to the top wall of each chamber at a position covering each perforated section. The two panels define a curved gap between them, thus holding a heated visor in the gap during a cooling process. The visors are heated at about 90.degree. C. to 150 .degree. C. for about 5-20 seconds in the visor shaping unit prior to being cooled in the cooling unit for about 10-30 seconds using cool air having a temperature of about 5-20 .degree. C.

Abstract: A free-size cap with a size adjusting band is disclosed. In the cap, six gores, integrated into a crown, are made of a stretchable woven fabric, with a weft directional elongation of the gores being higher than a warp directional elongation of the gores. A sweat band is attached along a lower edge of the integrated gores. The sweat band is made of a stretchable woven fabric, with a weft directional elongation of the sweat band being higher than the weft directional elongation of the gores. The warp directional elongation of the gores is 25%.+-.2%, and the weft directional elongation of the gores is 50%.+-.5%. The weft directional elongation of the sweat band is 65%.+-.5%. The free-size cap is thus primarily and manually adjusted in size by its size adjusting band and is finely and automatically adjusted in size by the elasticity of the stretchable woven fabric of both the crown and the sweat band. The cap thus allows a user to feel comfortable while wearing the cap.

Abstract: An auxiliary sweatband for headgear is disclosed. The auxiliary sweatband for headgear has a plurality of laminated normal non-woven fabric strips. A non-woven fabric strip is coated with a hydrophobic resin and is laminated at the back of the normal non-woven fabric strips. An unabsorbent non-woven fabric strip is laminated at the back of the non-woven fabric strip coated with a hydrophobic resin. A nylon woven fabric strip is coated with a polyurethane resin and is sewn with sewing threads on the laminated strips to surround the laminated strips except a front middle portion of the laminated strips. The laminated non-woven strips are bonded together. The overlapped strips are cut to be a little longer than the length of the inner edge of the visor of the cap and to have diagonal surfaces of 45.degree. at their ends.

Abstract: A device and method of shaping the visors of caps is disclosed. In the device, a visor shaping unit has a movable upper mold and a fixed lower mold. The upper mold, with a coil heater, is outwardly curved into a predetermined curvature at its lower surface and is operated by a hydraulic cylinder. The lower mold is inwardly curved into the same curvature as that of the upper mold at the top surface. The cooling unit has first to third chambers with a plurality of perforated sections being formed on the top wall of each of the chambers. Upper and lower panels are exteriorly attached to the top wall of each chamber at a position covering each perforated section. The two panels define a curved gap between them, thus holding a heated visor in the gap during a cooling process. The visors are heated at about 90.degree. C. to 150.degree. C. for about 5-20 seconds in the visor shaping unit prior to being cooled in the cooling unit for about 10-30 seconds using cool air having a temperature of about 5-20.degree. C.

Abstract: A free-size cap is disclosed. In the free-size cap of this invention, the gores of the crown are made of double-knit weft knitted fabrics having a weft directional elongation higher than 50%. The crown thus has a high ventilation effect, a high flexibility, a desired tightness, and allows a user to feel comfortable while wearing the cap. The free-size cap is also designed in that one reference-sized cap is commonly and freely usable by users having head sizes different from each other within a difference of about 12 cm. The free-size cap of this invention is further provided with a sweat band made of an elastic woven fabric having both a weft directional elongation higher than 65% and an elastic recovery higher than 95%, thus almost completely overcoming the problem of a row elastic recovery derived from the crown made of such weft knitted fabrics. The elastic woven fabric of the sweat band is manufactured by weaving latex-covered yarns as wefts and non-stretchable yarns as warps.

Abstract: A method and device for shaping the visors of caps is disclosed. In the method, the visor is curved into a predetermined curvature prior to being heated by hot steam having a temperature of about 100.degree. C. for about 5-150 seconds. The heated visor is cooled by a cool air current having a temperature of about 5.degree.-25.degree. C. for about 10-150 seconds. The device has heating and cooling units respectively connected to hot steam and cool air sources. A plurality of molds, used for shaping the visors, are received in at least one of the two units. Each of the molds includes two perforated panels, which are curved into the curvature and are assembled into a single body, with a plurality of spacers being interposed between the two panels and spacing the two panels apart from each other while def ining a curved gap between the two panels for receiving the visor of a cap.

Abstract: A free-size cap is capable of fitting wearers having a range of head sizes. The cap includes a multi-gore shell forming a crown portion, and a visor or bill portion connected to the crown portion. Ones of the gores forming the multi-gore shell are composed of a uniaxially stretchable woven material capable of being stretched only along the chordial axis of said multi-gore shell. The free-size cap has the aesthetic appeal of a fixed-size style cap, being capable of custom fitting all wearers within a predetermined range of head sizes, without requiring an adjustable fastener portion or an open portion on the back of the cap. An advantage of this free-size cap is that it is capable of custom fitting all wearers within a predetermined range of head sizes, without the drawback of changes in shape due to differences in head size.