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.

Description

RELATED APPLICATIONS

The present application is a continuation of U.S. patent application Ser. No. 14/462,168 entitled “Headwear System” that was filed on Aug. 18, 2014, which claims the benefit of U.S. Provisional Patent Application Ser. No. 61/867,084, filed Aug. 18, 2013, entitled “Flexible Fit Cap with Memory Foam Sweatband,” the disclosures of which are herein incorporated by reference.

SUMMARY

In some aspects, exemplary embodiments include a cap that is configured to be worn on a wearer's head. The cap 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.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 illustrates a portion of an example headwear system configured in accordance with some embodiments.

FIG. 2 is a cross-section view of an example headwear system arranged in accordance with various embodiments.

FIG. 3 shows a cross-section view of an example headwear system configured in accordance with assorted embodiments.

FIGS. 4A-4D respectively display different views of portions of an example headband that may be utilized in a headwear system in accordance with some embodiments.

FIG. 5 conveys a top view of a portion of an example headwear system configured in accordance with various embodiments.

FIG. 6 is a block representation of a portion of an example headwear system arranged in accordance with assorted embodiments.

FIG. 7 provides a flow chart of an example headwear utilization routine that may be carried out in accordance with some embodiments.

FIG. 8 is bottom view of a baseball cap constructed in accordance with another embodiment.

FIG. 9 is a bottom view of the baseball cap of FIG. 8.

FIG. 10 is a partial cut-away view of the sweatband of the baseball cap of FIG. 8.

FIG. 11 is a cross-sectional view of the front portion of the sweatband of FIG. 10.

FIG. 12 is a cross-sectional view of the back portion of the sweatband of FIG. 10.

FIG. 13 is a partial cut-away view of an alternate embodiment of the sweatband of FIG. 8.

FIG. 14 is a cross-sectional view of the sweatband of FIG. 13.

DETAILED DESCRIPTION

Various embodiments of the present disclosure generally relate to structure and function of a headwear system. Items of headwear, such as sports caps, visors, and headbands, can be symbols of fashion. However, due to different people's heads being different shapes and sizes, it can be difficult to properly fit headwear, which can be detrimental to a person's fashion. The ability to customize headwear can complement properly fitting headwear to optimize a person's fashion. Hence, headwear configured to properly fit a user while providing customizable features is a consumer and industry interest.

Accordingly, assorted embodiments configure a headwear system with a headband that fits a head of a user. At least one compliant portion is attached to the headband with a fastener. The compliant portion temporarily conforms to the head of the user in response to being positioned on the user's head. A medallion can be affixed to a bill extending from the headband and be arranged to extend through an aperture in an information feature that is also affixed to the bill. The compliant portion can allow headwear to fit a diverse variety of head shapes and sizes. The ability to customize the position of the medallion on the bill can allow a user to configure the headwear for various fashion styles and preferences.

FIG. 1 shows an example headwear system 100 arranged in accordance with various embodiments to provide a properly fitting headband 102 and a bill 104 that can be customized. As shown, the headwear system 100 is constructed as a sports cap, such as a baseball hat, that is defined by a body 106 that is constructed of one or more gores meeting at a crown 108. The gores of the body 106 may be any shape, size, orientation, and material, which gives the headband 102 a size and shape. It is contemplated that the headband 102 and body 106 are configured to be flexible, rigid, or a combination of the two to facilitate comfort, fashion, and universal fitment.

Although the bill 104 can be manipulated and formed into a variety of different shapes due to its semi-rigid construction, various embodiments incorporate at least one information feature 110 that adheres to the bill 104 and conveys an unlimited amount of information. As a non-limiting example, the information feature 110 can be graphics, logos, text, braille, and holographics that can convey information about the headwear system 100, such as a sports team, a charitable organization, and advertising. The information feature 110 can be shaped to cover some or substantially all of at least one surface of the bill 104, such as having a shape that matches the shape of the bill 104, to provide a large curvilinear or planar surface to convey information. The ability to tune the information feature 110 for size, shape, and material allows information to be efficiently and prominently displayed to others for a variety of purposes, such as fashion and information pertinent to selling the headwear system 100 to a user.

While the information feature 110 can provide fashion for some users, some embodiments configure the feature 110 to be removable by providing an adhesive portion that can allow the feature 110 to be selectively removed and moved at will. That is, portions of the information feature 110 can have adhesive that temporarily attaches the feature 110 to the bill 104 and allows the feature 110 to be moved to any region of the bill 104 or body 106. The ability to remove and relocate the information feature 110 can be also provided in a medallion 112 that continuously extends through an aperture 114 in the information feature 110. The medallion 112 can be any size, shape, material, and position on the bill 104 or body 106.

In some embodiments, the medallion 112 is a rigid material resembling a logo, which may represent a company, sports team, fictional character, and slogan without limitation. The combination of the medallion 112 and information feature 110 can allow multiple different fashion, advertising, and information to be conveyed concurrently. However, a user may not like the size or information conveyed on either the information feature 110 or medallion 112. Accordingly, the medallion 112 and information feature 110 can be removed individually without altering the position of the other aspect. For example, the aperture 114 allows the information feature 110 to be removed from the bill 104 without disturbing the medallion 112.

FIG. 2 displays a cross-sectional view of an example headwear system 120 configured in accordance with some embodiments to provide a headband 122 that continuously and circumferentially extends around an inner region 124 defined by a body 126. A bill 128 extends from the body 126 and has an information feature 130 and medallion 132 concurrently displayed on an exterior surface 134. It is contemplated that the information feature 130, medallion 132, or additional adhesive aspects can be attached to an interior surface 136 of the bill 128, which may enhance fashion and safety in various headwear system 120 applications.

The headband 122 can be constructed in an unlimited variety of fixed, flexible, and adjustable sizes. For instance, the headband 122 can sized to be a predetermined diameter, flexible to a variety of different diameters, and adjustable through a fastener system to a selected diameter. With the diverse variety of head sizes, hair styles, and comfort, a user may find the headband 122 unsatisfactory despite the ability to flex and adapt to a user's head. It is contemplated that a flexible headband 122 can be too constrictive for some users and lose its elasticity through trauma and use. Therefore, various embodiments configure the headband with a compliant portion that conforms to a user's head with optimized comfort, longevity, and customization.

FIG. 3 shows a cross-section view of an example headwear system 140 that is constructed and operated in accordance with various embodiments. The headwear system 140 has a body 142 that defines an inner region 144 that is partially or completely surrounded by a headband 146. A bill 148 continuously extends from the body 142 and has a medallion 150 positioned on an exterior surface 152. It is noted that the bill does not have an information feature, such as feature 110 of FIG. 1, but can be assumed that an information feature was previously present and removed from the bill, or not ever present.

The headband 146 can be configured with any combination of rigid, flexible, and semi-rigid materials that are layered or individually presented to predetermined portions of the headband 146. In accordance with some embodiments, a compliant portion 154 of the headband 146 can be positioned proximal the bill 148 and provide material that conforms to a user's head, such as cloth or foam, with minimal pressure applied to the head, which contrasts elastic, flexible headbands that can apply too little or too much pressure that results in an uncomfortable experience for a user.

Various embodiments incorporate the compliant portion 154 into the headband 146 by being sewn into a cloth or elastic strip, as shown in FIG. 3, while other embodiments configure the compliant portion 154 to be an additional component that can be attached in any position around the headband 146. The ability to tune the configuration of the compliant portion 154 for position, material, and presentation in relation to a user's head allows the headwear system 140 to be customized for fit and fashion. For example, the compliant portion 154 may be tuned to allow the headwear system 140 to be securely and comfortably worn in non-traditional manners, such as backwards, sideways, and tilted. Such secure and comfortable fitment can be attributed to the default or customized position and configuration of the compliant portion 154. That is, the compliant portion 154 may be removed, replaced, and reattached in different locations that can provide optimized fitment for a virtually any user's head.

In an example embodiment, the headband 146 is configured with a compliant portion 154 that continuously extends around the entire circumference of the body 142 and has different thicknesses, as measured from the internal surface 156 of the body 142 towards a center of the headband 146 along the Z axis. The different headband 146 and compliant portion 154 thicknesses can be positioned at locations that traditionally receive pressure and induce discomfort, such as along the temporal and forehead regions of a user's head. The compliant portion 154 may further be configured with a memory foam material construction, such as a low resilience polyurethane foam, that deforms in response to contact with a user's head and subsequently returns to a different default shape once the headwear system 140 is removed from the user's head.

FIGS. 4A-4D respectively illustrate different views of an example compliant portion 160 configured in accordance with various embodiments to be permanently or temporarily incorporated into a headwear system. FIG. 4A shows a top view of the compliant portion 160 that has a tuned shape and size to continuously extend around some, but not all, of the circumference of a headband, as represented by segmented line 162. The compliant portion 160 is configured with a thickness 164 that may be uniform or varying throughout the compliant body 166. A separate second compliant portion 167 can be positioned on the headband. It is contemplated that the compliant portion 160 can have a diameter 168 that is the same as the headband. It is further contemplated that the compliant portion may be interconnected into a continuous circular, or spheroid, shape by attaching two ends of the compliant body 166 via a seam cover 170.

The tuned size and position of the compliant portion 160 in a headband can allow the headband to conform to the user's head while maintaining rigidity through the portions of the headband that do not contain material that deforms to conform to the user's head. In other words, the compliant body 166 can have a size and shape that is selected in relation to the overall construction of the headband to provide secure and comfortable fitment with a user's head while providing rigidity that maintains the headwear system in place, particularly during movement of the user.

FIG. 4B is a side view block representation of the compliant portion 160 that shows how the compliant body 166 can be shaped to provide a carrier portion 172 with a uniform thickness along the Y axis that is disposed between connection tabs 174. The carrier portion 172 and tabs 174 can each be constructed of an elastic material that applies pressure to a foam insert 176 to induce the foam insert 176 to contact a user's head and deform when worn. The carrier portion 172 has a length 178 that is greater than the length 180 of the foam insert 176, but such configuration is not limiting as the foam insert 176 may continuously or discontinuously extend beyond the carrier length 178, such as into the tabs 174.

It is noted that various portions of the compliant portion 160 can have one or more fastening means attached thereto. For example, but in no way limiting, hook-and-loop, magnets, and adhesives can be positioned on various locations on the compliant portion 160 to allow for selective installation and removal from a headband. Some embodiments configure the connection tabs 174 to fasten together to form a loop, such as with the aid of a seam cover 170. The tuned size and shape of the connection tabs 174 can allow the compliant portion 160 to be easily attached, removed, and repositioned anywhere on a headband to provide customizable fitment for a headwear system.

FIG. 4C displays a cross-section view block representation of the compliant portion 160 that illustrates how the foam insert 176 can consist of a number of different layers that can be horizontally stacked along the Z axis or vertically stacked along the X axis. As shown, the compliant body 166 is shaped to present the connection tabs 174 to allow efficient installation and removal of the compliant portion 160 along any portion of a headband, such as within a headband flap. It is understood that the foam insert 176 may deform and present uncomfortable undulations in the headband. Accordingly, the foam insert 176 is configured with an overall thickness 182 that compensates for deformation of the first 184 and second 186 foam layers to provide a uniform headband surface that aligns the carrier 188 and foam 190 surfaces along the Z axis when the compliant portion 160 is worn, as depicted in FIG. 4D.

Through various embodiments, the foam insert 176 can have any number of dissimilar layers that are tuned to provide optimized fitment without being bulky, heavy, or awkward. That is, the first foam layer 184 can be constructed with a different density, weight, material, and thickness than the second foam layer 186. For example, the first foam layer 184 may have a lower density than the second foam layer 186 to allow more efficient heat dissipation from the user's head while providing pressure-sensitive deformation in response to contact with the user's head. It is contemplated that the combination of different foam layers 184 and 186 can provide optimized headband fitment by presenting multiple different structures that deform and react to a user's head differently.

FIG. 5 is a top view of a portion of an example headwear system 200 that has a plurality of medallions and information feature positioned on a bill 202. It is to be understood that any number of similar and dissimilar medallions and information features can be incorporated into the headwear system 200. The non-limiting embodiment shown in FIG. 5 illustrates how a first 204 and second 206 information features can be separated by a seam 208 and arranged with mating surfaces 210 that correspond and form a single comprehensive information structure. Such comprehensive information structure can convey an unlimited variety of graphics and text that can be easily manipulated by removing one information feature while leaving another information feature on the bill 202.

Regardless of the number and subject matter on the information features 204 and 206, at least one medallion can extend through an aperture 212 in the information feature. A first medallion 214 is configured with a first shape and size that differs from the configurations of the second 216, third 218, and fourth 220 medallions. The different shapes of the medallions 214, 216, 218, and 220 are not required or limiting, but show how differently configured medallions and apertures 212, such as squares, parallelograms, rhomboids, octagons, and trapezoids, can be incorporated into the headwear system 200 and aligned along any longitudinal axis, such as axis 222 that is angled with respect to the Z and X axes. Various embodiments configure the various medallions to have shapes and sizes that can interconnect and form a collective image, shape, or design in response to a user removing and repositioning at least one medallion.

FIG. 6 displays a cross-section view block representation of a portion of an example headwear system 230 configured in accordance with some embodiments to have a bill 232 on which an information feature 234 and medallion 236 are respectively attached. It is noted that the bill 232 has a uniform thickness 238 along the Y axis, but such configuration is not required as a varying thickness may allow the bill 232 to be controlled and manipulated more easily. The information feature 234 is configured as a lamination of a fastener layer 240, such as an adhesive, hook-and-loop, magnetic, or tongue-and-groove fastener, and an exterior layer 242 that collectively have a information thickness 244. The information feature has an information surface 246 that is opposite the bill 232 and conveys graphics and text that may be printed, imprinted, and holographically projected.

The medallion 236 is also configured with a fastener layer 248 that contacts the bill 232 and positions the exterior layer 250 to face away from the bill 232. The various layers of the information feature 234 and medallion 236 can be tuned to have different thicknesses 244 and 252 that may convey texture and design that are fashionable and eye-catching. As shown the medallion 236 extends a certain distance 254 above the information feature 234, such as 1 cm, through the aperture 256. The ability to manipulate the fastening means and thicknesses of the information feature 234 and medallion 236 can convey a diverse variety of textures, graphics, and text that can be selectively removed, reorganized, and reattached at the will of the user to produce customized headwear.

FIG. 7 is a flow chart of an example headwear utilization routine 260 that may be conducted in accordance with various embodiments to provide customized and comfortable headwear. Initially, step 262 attaches a compliant portion to a headband. Step 262 may be a permanent attachment, such as stitching the compliant portion into the headband, or a temporary attachment where the compliant portion can be subsequently removed or repositioned by a user to optimize comfort and fitment. Step 264 then positions at least one information feature and medallion on the bill of the headwear.

Although the user may wear the headwear with the information feature and medallion attached to the bill, various embodiments conduct step 266 where at least one information feature is removed while the medallion is unaltered. Next, decision 268 determines if the medallion is to be moved. A decision to move the medallion advances routine 260 to step 270 where the medallion is repositioned on a selected portion of the bill, such as the exterior or interior surfaces of the bill. At the conclusion of the customization of the medallion placement in step 270, or if the medallion is maintained at its original location, step 272 subsequently positions the headwear on the head of a user in a manner that deforms the compliant portion to provide a secure and comfortable fit of the headband.

It is noted that the various steps and decision of routine 260 are not required or limiting. As such, any aspect of routine 260 can be changed and removed just as any number of decisions and steps can be added. For example, additional steps may follow step 270 to reposition a plurality of medallions in a collective configuration that may extend into the body of the headwear.

Referring to FIG. 8, shown therein is a cap 500 constructed in accordance with an alternate embodiment of the present invention. The cap 500 includes a crown 502 constructed from a plurality of substantially triangular gores 504. It will be understood that the crown 502 is adequately shaped and sized to receive the wearer's head. The cap 500 also includes a bill 506 that extends from the front of the crown 502. As shown, the bill 506 is slightly contoured in a parabolic fashion. Although the present invention as described herein is embodied within the cap 500, it will be understood that the present invention can also be applied to other forms of headwear including, but are not limited to, cowboy hats and berets.

In the presently preferred embodiment, the crown 502 is preferably constructed from a material that permits a flexible fit to adjust to the unique size of the wearer's head. To enable lateral stretching about the circumference of the crown 502, as indicated by arrows 508, an elastic fiber is woven into the weft of the material selected to construct the gores 504. Similarly, if a longitudinal flex is desired, an elastic fiber can be woven into the warp of the material used to construct the gores 504. It will be understood that the cap 500 can also be constructed to have both lateral and longitudinal elasticity.

In another embodiment, the two front gores 504 are lined with a semi-rigid backing that provides structure and shape to the front of the crown 502. In this embodiment, it is not necessary that the two front gores 504 be fabricated from a stretchable material. In a particularly preferred embodiment the two front gores 504 are provided with a buckram backing. Alternatively, all of the gores 504 are manufactured without the rigid backing to provide an unstructured cap 500.

Turning to FIG. 9, shown therein is a bottom view of the cap 500. As shown in FIG. 9, the cap 500 further includes a sweatband 510 that is circumferentially disposed about the inside of the bottom edge of the crown 502. In the presently preferred embodiment, the sweatband 510 includes an arcuate front portion 512 connected to an arcuate back portion 514 with a seam cover 516. As explained herein, the back portion 514 is preferably constructed to permit biaxial flexibility, while the front portion 512 provides a degree of compliance and flexibility in a radial direction.

Referring to FIG. 10, shown therein is a partial view of the sweatband 510 in partial cut-away view constructed in accordance with a first preferred embodiment. FIGS. 11 and 12 present cross-sectional views of the front portion 512 and back portion 514, respectively. The back portion 514 includes a rear contact layer 520 attached to a concealed elastic support layer 522. The bottom edges of the rear contact layer 520 and elastic support layer 522 are attached to the lower perimeter of the crown 502. The top edges of the rear contact layer 520 and elastic support layer 522 are preferably not sewn to the inside surface of the crown 502.

The front portion 512 of the sweatband 510 preferably includes an exposed front contact layer 524, a concealed backing layer 526 and an intermediate foam layer 528. The backing layer 526 can be attached at its top and bottom edges to the mating top and bottom edges of the front contact layer 524 with stitching 530. The lower edges of the front contact layer 524 and backing layer 526 are collectively joined with the lower edge of the crown 502. In an alternate preferred embodiment, the backing layer 526 is not included in the front portion 512. In the presently preferred embodiment, the rear contact layer 520, front contact layer 524 and backing layer 526 are constructed from a breathable polyester fabric that exhibits good durability.

In a particularly preferred embodiment, the rear contact layer 520, front contact layer 524 and backing layer 526 are constructed from the same material that is used to fabricate the gores 504. As such, the rear contact layer 520, front contact layer 524 and backing layer 526 can be constructed from scrap or other portions of the same material used to construct the gores 504, thereby providing a lower cost of manufacture. Unlike similar prior art sweatbands, however, the rear contact layer 520 is not created by simply folding a portion of the gores 504 inside the crown 502. As such, the rear contact layer 520 does not include gore seams or gore reinforcements that tend to create uncomfortable lumps in the sweatband 510.

The elastic support layer 522 is preferably constructed from thin elastic webbing or spandex. The elastic support layer 522 provides additional structure to the rear contact layer 520 without inhibiting the overall circumferential flexibility of the sweatband 510. In an alternate preferred embodiment, the elastic support layer 522 is not included in the back portion 514.

The intermediate foam layer 528 is preferably constructed from a low-resilience polyurethane foam. Suitable foam layers may include those products referred to as “memory foam.” In a particularly preferred embodiment, the intermediate foam layer 528 is manufactured from a higher-density memory foam that softens in reaction to heat from the wearer's head, thereby allowing it to mold to a warm body in a few minutes. In an alternative embodiment, the intermediate foam layer 528 is constructed from a lower-density foam that is pressure-sensitive and molds quickly to the shape of the wearer's head pressing against it, returning to its original shape once the pressure is removed.

The intermediate foam layer 528 does not present a high degree of stretching in the axial directions, but provides the sweatband 510 with an additional degree of flexibility in the radial direction. By compressing in response to pressure and heat exerted by the wearer's head, the intermediate foam layer 528 allows the sweatband 510 to comfortably conform to a larger number of head sizes. The ability for a single size cap 500 to comfortably conform to a larger number of heads presents a significant advance over the prior art. Moreover, the combination of the axially stretchable back portion 514 with the radially compliant front portion 512 provides a sweatband 510 and cap 500 that is comfortable to wear and is securely fitted to the wearer's head, but does not create irritation or marking on the wearer's forehead.

As shown in FIG. 10, the front portion 512 and the back portion 514 of the sweatband 510 are preferably connected with the seam cover 516. The seam cover 516 is preferably rectangular in shape, having a first side connected to the front portion 512 and an opposed second side connected to the back portion 514. To reduce the thickness of the sweatband 510, it is preferred that the front portion 512 and back portion 514 not overlap. However, to facilitate manufacture, it may be desirable to slightly overlap the front and back portions 512, 514 before affixing the seam cover 516.

It is also preferred that the seam cover 516 have a low profile above the sweatband 510 and be manufactured from a thin piece of fabric that is tear and wear resistant. Suitable fabrics include polyester and nylon blends. In an alternative embodiment, the seam cover 516 can be fabricated from a flexible material that stretches when subjected to a tensile load from the front portion 512 and back portion 514. It will be noted that the seam cover 516 can also be used to display a logo or design.

Turning to FIGS. 13 and 14, shown therein are partial cut-away and cross-sectional views, respectively, of an alternate embodiment of the front portion 512 of the sweatband 510. In the alternate embodiment depicted in FIG. 8, the front portion 512 includes diamond quilted stitching 532 that extends through the front contact layer 524, intermediate foam layer 528 and backing layer 526. The diamond quilted stitching 532 generally decreases the tendency of the intermediate foam layer 528 to “bulge” through the front contact layer 524 and backing layer 526 and presents an attractive sweatband 510.

Through the various embodiments of a headwear system, comfort and customization are optimized to provide a unique and fashionable article. The tuned configuration of a compliant portion of a headband can provide material that deforms to conform to the shape and size of a user's head, which increases fitment of the headwear as well as allowing secure non-traditional headband orientations. The incorporation of at least one information feature and medallion on a bill or body of the headwear system can provide advertising and fashion components that can be selectively removed and reorganized to convey a customized, fashionable appearance.

Numerous characteristics and advantages of various embodiments of the present disclosure have been set forth in the foregoing description, together with structural and functional details. Nevertheless, this detailed description is illustrative only, and changes may be made in detail, especially in matters of structure and arrangements of parts within the principles of the present disclosure to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.

Claims

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.