The present invention generally relates to the production of knitted caps that are lightweight and breathable. Generally, the manufacturing process for producing the knitted caps involves: (1) applying a continuous wax coating onto a polyester yarn; (2) twisting the yarn with one or more additional yarns to produce a twisted yarn; (3) knitting the twisted yarn into a knitted article; (4) sewing the knitted article into a headwear body; and (5) finishing the headwear body to form the headwear article. The resulting headwear articles can be in the form of caps that exhibit superior breathability and moisture wicking capabilities.

The present invention generally relates to the production of knitted caps that are lightweight and breathable. Generally, the manufacturing process for producing the knitted caps involves: (1) applying a continuous wax coating onto a polyester yarn; (2) twisting the yarn with one or more additional yarns to produce a twisted yarn; (3) knitting the twisted yarn into a knitted article; (4) sewing the knitted article into a headwear body; and (5) finishing the headwear body to form the headwear article. The resulting headwear articles can be in the form of caps that exhibit superior breathability and moisture wicking capabilities.

A baseball cap (100) and method of assembling thereof is provided. The cap (100) includes a single-panel crown (110) that is formed from a single sheet or single piece of stretchable fabric, such as using heat pressing techniques. The single-panel crown (110) has a hemispherical shape. The cap (100) further includes a support layer (230), such as made from buckram, which is attached to an interior, front portion of the single-panel crown (110), and a visor (120) and an elastic band (260) which are attached to the single-panel crown (110).

A baseball cap (100) and method of assembling thereof is provided. The cap (100) includes a single-panel crown (110) that is formed from a single sheet or single piece of stretchable fabric, such as using heat pressing techniques. The single-panel crown (110) has a hemispherical shape. The cap (100) further includes a support layer (230), such as made from buckram, which is attached to an interior, front portion of the single-panel crown (110), and a visor (120) and an elastic band (260) which are attached to the single-panel crown (110).

A baseball cap and method of assembling thereof is provided. The cap includes a crown that is formed from a single sheet or single piece of stretchable fabric, such as using heat pressing techniques. The cap further includes a support layer, such as made from buckram, which is attached to an interior, front portion of the crown, and a visor and a band which are attached to the crown. The crown has a hemispherical shape. In one example, the crown can include a back portion thereof which has been removed to form an open area across which an adjuster is attached. In another example, a front portion of the single-panel crown can be removed and replaced with a front panel made of a different material to form a modified crown.

A baseball cap and method of assembling thereof is provided. The cap includes a crown that is formed from a single sheet or single piece of stretchable fabric, such as using heat pressing techniques. The cap further includes a support layer, such as made from buckram, which is attached to an interior, front portion of the crown, and a visor and a band which are attached to the crown. The crown has a hemispherical shape. In one example, the crown can include a back portion thereof which has been removed to form an open area across which an adjuster is attached. In another example, a front portion of the single-panel crown can be removed and replaced with a front panel made of a different material to form a modified crown.

A baseball cap and method of assembling thereof is provided. The cap includes a crown that is formed from a single sheet or single piece of stretchable fabric, such as using heat pressing techniques. The cap further includes a support layer, such as made from buckram, which is attached to an interior, front portion of the crown, and a visor and a band which are attached to the crown. The crown has a hemispherical shape. In one example, the crown can include a back portion thereof which has been removed to form an open area across which an adjuster is attached. In another example, a front portion of the single-panel crown can be removed and replaced with a front panel made of a different material to form a modified crown.

A baseball cap and method of assembling thereof is provided. The cap includes a single-panel crown that is formed from a single sheet or single piece of stretchable fabric, such as using heat pressing techniques. The single-panel crown has a hemispherical shape. The cap further includes a support layer, such as made from buckram, which is attached to an interior, front portion of the single-panel crown, and a visor and an elastic band which are attached to the single-panel crown.

A ball cap with a concealed opening that allows for a greater variety of hairstyles to be worn while simultaneously retaining the general shape, appearance, and functionality of a typical ball cap. The concealed opening is hidden in a default configuration of the hat, but it can be selectively opened to allow for hair such as a ponytail to pass through. The ball cap can include a protective coating on the sweatband to prevent makeup, sweat, and dirt from soiling the sweatband.

A ball cap with a concealed opening that allows for a greater variety of hairstyles to be worn while simultaneously retaining the general shape, appearance, and functionality of a typical ball cap. The concealed opening is hidden in a default configuration of the hat, but it can be selectively opened to allow for hair such as a ponytail to pass through. The ball cap can include a protective coating on the sweatband to prevent makeup, sweat, and dirt from soiling the sweatband.