Composite waterproof breathable elastic hats and methodology and dies used to manufacture such hats

Abstract

A composite waterproof breathable elastic hat comprising a knitted outer layer ( 5 ), and/or lining ( 6 ) and a waterproof breathable membrane hood ( 7 ) in which the waterproof breathable membrane hood ( 7 ) is attached to an attachment surface on the outside of the lining ( 6 ) and/or to an attachment surface on the inside of the outer layer ( 5 ). A method of manufacturing a composite waterproof breathable elastic hat and a die ( 8 ) for the manufacture of a composite waterproof breathable elastic hat are also provided.

What is claimed is: 
     
         1 . A composite waterproof breathable elastic hat comprising a knitted outer layer, a lining and a waterproof breathable membrane hood, in which the waterproof breathable membrane hood is attached to an attachment surface on the outside of the lining and/or to an attachment surface on the inside of the outer layer. 
     
     
         2 . A composite waterproof breathable elastic hat as claimed in  claim 1 , in which the lining is knitted, made of a highly elastic spandex knit or made of woven cloth cut and stitched. 
     
     
         3 . A composite waterproof breathable elastic hat as claimed in  claim 1 , in which the outer layer is made of a highly elastic spandex knit or of woven cloth cut and stitched. 
     
     
         4 . A composite waterproof breathable elastic hat as claimed in  claim 1 , in which the outer layer is attached to the lining. 
     
     
         5 . A composite waterproof breathable elastic hat as claimed in  claim 4 , in which the outer layer is stitched to the lining. 
     
     
         6 . A composite waterproof breathable elastic hat as claimed in  claim 1 , in which the outer layer is stretchable from a relaxed condition to a stretched condition. 
     
     
         7 . A composite waterproof breathable elastic hat as claimed in  claim 6 , in which the lining is stretchable from a relaxed condition to a stretched condition. 
     
     
         8 . A composite waterproof breathable elastic hat as claimed in  claim 7 , in which the waterproof breathable membrane hood has a greater surface area than either of the outer layer and lining when said outer layer and lining are in their relaxed condition. 
     
     
         9 . A composite waterproof breathable elastic hat as claimed in  claim 8 , in which the waterproof breathable membrane hood is non-elastic or substantially non-elastic. 
     
     
         10 . A composite waterproof breathable elastic hat according to  claim 1 , in which the waterproof breathable membrane hood is attached to the lining and/or the outer layer at a plurality of spaced locations. 
     
     
         11 . A composite waterproof breathable elastic hat as claimed in  claim 10 , in which the waterproof breathable membrane hood is attached to the lining and/or outer layer at a plurality of substantially uniformly spaced locations. 
     
     
         12 . A composite waterproof breathable elastic hat as claimed in  claim 10 , in which the waterproof breathable membrane hood is adhered to the lining and/or outer layer at a plurality of spaced locations over the attachment surface of one or both of the lining and outer layer. 
     
     
         13 . A composite waterproof breathable elastic hat as claimed in  claim 12 , in which the lining and/or outer layer is adhered with one or more of TPU [thermoplastic polyurethane], PES [polyester] and PA [polyamide, nylon]. 
     
     
         14 . A composite waterproof breathable elastic hat according to  claim 8 , in which the hat is stretchable from a resting condition in which, the outer layer and lining are in their relaxed condition and the waterproof breathable membrane hood has a wrinkled or generally corrugated conformation between the outer layer and the lining, and an extended condition in which the outer layer and lining are in their stretched condition and the waterproof breathable membrane hood is in a flat or less-wrinkled or less-corrugated conformation. 
     
     
         15 . A composite waterproof breathable elastic hat as claimed in  claim 14 , in which the waterproof breathable membrane hood has a bi-directional wrinkled or corrugated conformation when the hat is in the resting condition, from which the waterproof breathable membrane hood can move with the outer layer and lining when the outer layer and lining are extended to their stretched conditions as the hat is taken from its resting condition. 
     
     
         16 . A composite waterproof breathable elastic hat as claimed in  claim 1 , in which the waterproof breathable membrane hood comprises bonded layers pressed together using a high temperature sealing machine or a high frequency plastic bonding machine. 
     
     
         17 . A method of manufacturing a composite waterproof breathable elastic hat, the method comprising stretching a lining or outer layer over a die, positioning a waterproof breathable membrane hood over the lining or outer layer and stretching an outer layer or lining over the waterproof breathable membrane hood, attaching the lining and/or outer layer to the waterproof breathable membrane hood to form a hat structure which upon removal from the die contracts until the lining and outer layer are in a relaxed condition and the waterproof breathable membrane hood is located therebetween in a wrinkled or corrugated conformation. 
     
     
         18 . A method of manufacturing a composite waterproof, breathable elastic hat, the method comprising stretching a lining or outer layer over a die or mould, positioning a waterproof breathable membrane hood over the lining or outer layer, attaching the lining or outer layer to the waterproof breathable membrane hood to form a bi-layer, which upon removal from the die or mould contracts until the lining or outer layer is in a relaxed condition and the waterproof breathable membrane hood is attached to the lining in a wrinkled, puckered or corrugated conformation. 
     
     
         19 . A method as claimed in  claim 17 , in which the waterproof breathable membrane hood is positioned over the lining or outer layer in a relaxed, non-stretched condition. 
     
     
         20 . A method as claimed in  claim 17 , in which adhesive is applied to the lining and/or outer layer and/or waterproof breathable membrane hood at discrete, spaced locations. 
     
     
         21 . A method as claimed in  claim 20  in which the adhesive is applied prior to layering the waterproof breathable membrane hood and/or the lining and/or outer layer over the die. 
     
     
         22 . A method as claimed in  claim 20 , in which the adhesive is spotted, dusted and/or taped on the respective one or more of lining, outer layer and/or waterproof breathable membrane hood. 
     
     
         23 . A method as claimed in  claim 20 , in which the adhesive is melted or softened on the die to adhere the waterproof breathable membrane hood and/or the lining and/or outer layer together. 
     
     
         24 . A method as claimed in  claim 18 , in which the other of an outer layer or lining is positioned over the bi-layer to form a hat structure. 
     
     
         25 . A method as claimed in  claim 17 , in which the hat structure is stitched along or near its edge to form a hat. 
     
     
         26 . A hat structure for a composite waterproof breathable hat, the structure comprising an elastic outer layer or elastic lining and a non-elastic or substantially non-elastic breathable membrane hood attached to an attachment surface on the lining or outer layer. 
     
     
         27 . A die for the manufacture of a composite waterproof breathable elastic hat as claimed in  claim 1 , in which the die comprises a forming surface on which the hat or hat structure is formed, the forming surface being arranged and dimensioned to receive and form the waterproof breathable membrane hood in its relaxed condition. 
     
     
         28 . A die as claimed in  claim 27 , in which the die comprises a flat-plate die with the same flat dimensions as the waterproof breathable membrane hood.