Patent application title: Foam Mesh Cap
Kuan-Chang Chen (Taichung City, TW)
IPC8 Class: AA42B100FI
Class name: Apparel head coverings having crown and horizontally extending visor (e.g., baseball cap, etc.)
Publication date: 2011-03-17
Patent application number: 20110061144
The invention is related to a kind of foam mesh cap. The foam mesh cap
has a foam layer that is composed of two pieces of cloth at outer sides
and a piece of foam in the middle. Outside the foam layer there is an
exterior fabric layer. The three parts are sewed together to form a pad.
The two sides of the pad and multiple mesh sheets are sewed to form a cap
body. The cap body is then sewed to a cap peak to make the foam mesh cap.
As a result, the thick and firm pad can provide instant shape recovery
and increase product durability by preventing water from getting into
1. A foam mesh cap comprises: a cap peak; and a cap body sewed to the cap
peak and comprising a pad and at least a mesh sheet with the feature in
that the pad is composed of an exterior fabric layer, a foam layer and a
supporting piece, overlapping and sewed together.
2. According to claim 1 for the foam mesh cap, the supporting piece is a poly nylon pad.
3. According to claim 1 for the foam mesh cap, the supporting piece has multiple meshes.
4. According to claim 1 for the foam mesh cap, the foam layer further has a piece of foam and two pieces of cloth.
BACKGROUND OF THE INVENTION
 1. Field of the Invention
 The invention is related to a kind of foam mesh cap, especially one that can increase durability and have shape stability by elastic recovery.
 2. Description of the Prior Art
 Cap is a very common thing to wear in daily life. Its basic requirement is to fit with the user's head. Therefore a traditional mesh cap is mainly formed by sewing the front edge of cap body to a cap peak. A hard piece is sewed inside the cap peak. A pad in the front of the cap body connects to the cap peak. Multiple mesh sheets are sawed to the two sides of the pad.
 By the above design, the pad and the multiple mesh sheets after sewing form a concave cap body to fit with the user's head. However, after the inventor has studied the market and made further analysis, it is found that the above traditional mesh cap usually only uses an exterior fabric layer and a thin foam layer when cost is considered. The thin foam layer after a long time of use will sink and be very difficult to recover. As a result, the foam layer could be damaged or rupture. The product life is only about one year. Thus, such mesh cap structure needs further improvement.
SUMMARY OF THE INVENTION
 Knowing the drawbacks with the traditional mesh cap, the inventor has dedicated to its improvement and finally invented a new kind of foam mesh cap to have a desirable mesh cap structure.
 Thus, the objective for the invention is to provide a foam mesh cap that a supporting piece in the bottom of the pad can provide sufficient elastic recovery back to the original shape and air-permeation and sweat-repellency, and attain product durability.
 To achieve the above objective, a new kind of foam mesh cap is made by sewing an exterior fabric layer, a foam layer and a supporting piece.
 In realization of the invention, first, a thick and firm foam layer is formed by combining a supporting piece that has elastic structure with multiple meshes and a piece of foam that is within two pieces of cloth, and then an exterior fabric layer is sewed to the foam layer to form a pad.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
 The following provides detailed description for the invention with figures and embodiments.
 As shown in FIG. 1, the complete assembly of the invention is divided two major parts: cap peak (1) and cap body (2).
 As shown in FIG. 2, the supporting piece and the foam layer overlap in the pad. The supporting piece (213) is woven into net structure with multiple meshes (A) that provides the cap with strength for wrinkle resistance.
 As shown in FIG. 3, the enlarged localized view for the supporting piece and the foam layer of the pad mainly comprises: a cap peak (1) and a cap body (2) that is sewed to the back of the cap peak (1). The cap body (2) has a pad (21) to support the shape and provide aesthetics and durability and at least a permeable mesh sheet (22) that is sewed to both sides of the large area pad (21). Other mesh sheets (22) can be sewed to different area to form the cap shape that can fit with the user's head.
 The previously mentioned pad (21) is made by first overlapping an exterior fabric layer (211), a foam layer (212) and a supporting piece (213) and then sewing them together. The supporting piece (213) with multiple meshes (A) forms a large area net structure that effectively provides the pad (21) with elastic recovery strength to prevent wrinkles and maintain the original cap shape and aesthetics. The mesh (A) also has air permeability and odor repellency. In this embodiment, the supporting piece (213) is a poly nylon pad, but not limited to it.
 The previously mentioned foam layer (212) further has a piece of foam (B) and two pieces of cloth (C). The two pieces of cloth (C) are placed in the top and in the bottom, while the foam (B) is placed in the middle. A process will bond the three pieces together to provide buffering elasticity and comfort.
 Please refer to FIGS. 1, 2 and 3 for the above-mentioned structure. The exterior fabric layer (211) in the invention is in the top, and the foam layer (212) is in the middle, while the supporting piece (213) is in the bottom. The three layers first overlap and then are sewed to the above mentioned mesh sheet (22) to produce a cap body (2). The cap body (2) is then sewed to a cap peak (1) to produce a foam mesh cap.
 In summary, the product compared to the traditional mesh cap has thicker pad to instantly recover the shape and provide product durability by preventing moisture permeation. These benefits with the product have not been found in publications or other products. The product shall be considered an excellent innovation and meet the requirements for patent application, which is thereafter submitted accordingly.
 (1) The designated diagram for the present invention is FIG. (1).  (2) The legends for the components  (1) cap peak  (2) cap body
BRIEF DESCRIPTION OF THE DRAWINGS
 FIG. 1 is the diagram for the completed assembly for the invention.
 FIG. 2 is the diagram for the supporting piece and the foam layer overlapping in the pad for the invention.
 FIG. 3 is the enlarged localized view for the supporting piece and the foam layer of the pad for the invention.
DESCRIPTION OF MAIN COMPONENTS
TABLE-US-00001  (1) cap peak (2) cap body (21) pad (211) exterior fabric layer (212) foam layer (213) supporting piece (22) mesh sheet (A) mesh (B) foam (C) cloth
Patent applications in class Having crown and horizontally extending visor (e.g., baseball cap, etc.)
Patent applications in all subclasses Having crown and horizontally extending visor (e.g., baseball cap, etc.)