A manufacturing method including providing a mold including at least two mold parts having first and second molding surfaces which are complementarily profiled to give shape to headwear; shaping a first substrate in the mold resulting in the first substrate having a non-planar profile which matches at least a portion of the profile of the molding surfaces; shaping a second substrate in the mold resulting in the second substrate having a non-planar profile which matches the profile of the molding surfaces; overlaying the first substrate on the second substrate and matching their non-planar profile to form a combined substrate; placing a third substrate in the mold with the combined substrate, sandwiching the first substrate; and shaping the third substrate with the combined substrate in the mold resulting in the third substrate having a non-planar profile which matches the profile of the molding surfaces, thereby forming a seamless structure for the headwear.

A manufacturing method including providing a mold including at least two mold parts having first and second molding surfaces which are complementarily profiled to give shape to headwear; shaping a first substrate in the mold resulting in the first substrate having a non-planar profile which matches at least a portion of the profile of the molding surfaces; shaping a second substrate in the mold resulting in the second substrate having a non-planar profile which matches the profile of the molding surfaces; overlaying the first substrate on the second substrate and matching their non-planar profile to form a combined substrate; placing a third substrate in the mold with the combined substrate, sandwiching the first substrate; and shaping the third substrate with the combined substrate in the mold resulting in the third substrate having a non-planar profile which matches the profile of the molding surfaces, thereby forming a seamless structure for the headwear.

A method is providing for manufacturing an integrally formed cap, the method comprising: in step 1, providing a shell fabric B and a thermoplastic lining fabric C, superposing the shell fabric on a surface of the lining fabric and tightly attaching the shell fabric to the lining fabric, to obtain the fabric A needed, and providing the shaping mold matched with the shape of a cap; in step 2, cutting the fabric A obtained in Step 1 into set dimensions; and in step 3, tightly attaching the fabric A cut in Step 2 onto the shaping mold obtained in Step 1, thermally shaping the fabric A by a container, so as to integrally shape the fabric A into the cap. With the method of the invention, the production speed and quality stability can be increased, the production cost reduced, and the production process is energy-saving and environment-friendly.

A method is providing for manufacturing an integrally formed cap, the method comprising: in step 1, providing a shell fabric B and a thermoplastic lining fabric C, superposing the shell fabric on a surface of the lining fabric and tightly attaching the shell fabric to the lining fabric, to obtain the fabric A needed, and providing the shaping mold matched with the shape of a cap; in step 2, cutting the fabric A obtained in Step 1 into set dimensions; and in step 3, tightly attaching the fabric A cut in Step 2 onto the shaping mold obtained in Step 1, thermally shaping the fabric A by a container, so as to integrally shape the fabric A into the cap. With the method of the invention, the production speed and quality stability can be increased, the production cost reduced, and the production process is energy-saving and environment-friendly.

An article configured to fit over a wearer's head, or head and hat, in a manner to create shade for at least the wearer's ears and neck. The article includes a first circular member defining a first central opening and second circular member defining a second central opening. The first circular member includes a series of cuts about an inner edge proximate to the first central opening with the second circular member joined to the first circular member proximate to the series of cuts. One or more size adjustment fasteners may be employed to accommodate different head sizes.

An article configured to fit over a wearer's head, or head and hat, in a manner to create shade for at least the wearer's ears and neck. The article includes a first circular member defining a first central opening and second circular member defining a second central opening. The first circular member includes a series of cuts about an inner edge proximate to the first central opening with the second circular member joined to the first circular member proximate to the series of cuts. One or more size adjustment fasteners may be employed to accommodate different head sizes.

A shock absorbing cap provides shock abortion in the space between the interior of a traditional safety helmet and the head of the wearer. The cap has a first region next to the scalp which is made of 100% knitted cotton for comfort and the absorption of sweat. A second region is made of 100% wool fleece braided fiber bundles that extend alternately in longitudinal and lateral directions sufficiently to nearly fill the space. The outermost region is made of one or more layers of braided 100% carbon fiber bundles, which run the opposite direction of the last wool lock. In an alternative, the first region is used but the second region completely fills the space with woven aramid and carbon fiber squares laid on top of each other and sewn together. The uppermost portion is laser cut for a tight but comfortable fit under the helmet.

A shock absorbing cap provides shock abortion in the space between the interior of a traditional safety helmet and the head of the wearer. The cap has a first region next to the scalp which is made of 100% knitted cotton for comfort and the absorption of sweat. A second region is made of 100% wool fleece braided fiber bundles that extend alternately in longitudinal and lateral directions sufficiently to nearly fill the space. The outermost region is made of one or more layers of braided 100% carbon fiber bundles, which run the opposite direction of the last wool lock. In an alternative, the first region is used but the second region completely fills the space with woven aramid and carbon fiber squares laid on top of each other and sewn together. The uppermost portion is laser cut for a tight but comfortable fit under the helmet.

A swim cap and a method for producing the same is disclosed. A lower portion of the swim cap is shaped as a band, and an upper portion is dome shaped. Stitching joins the lower portion to the upper portion along a horizontal seam. At least two pieces of the lower portion, and a first and second piece of the upper portion, are joined to one another with stitching along a first vertical seam. The second and a third piece of the upper portion are joined to one another with stitching along a second vertical seam. The lower and upper portions are comprised of a substantially waterproof material.

A swim cap and a method for producing the same is disclosed. A lower portion of the swim cap is shaped as a band, and an upper portion is dome shaped. Stitching joins the lower portion to the upper portion along a horizontal seam. At least two pieces of the lower portion, and a first and second piece of the upper portion, are joined to one another with stitching along a first vertical seam. The second and a third piece of the upper portion are joined to one another with stitching along a second vertical seam. The lower and upper portions are comprised of a substantially waterproof material.