Patent ID: 8627515

Claim:
A method of constructing a high fashion, crushable, lightweight, collapsible hat, with an initial shape, having a plurality of elements comprising a crown, a brim, and a plurality of bands, each element assembled from a panel cut from a lamination, the lamination having a pair of woven fabric layers, each woven fabric layer having a straight-of-grain line, a plurality of adhesive layers and at least one open-cell foam layer, the open-cell foam layer having a pair of plane surfaces, the open-cell foam layer adhered between the pair of woven fabric layers by the adhesive layers, comprising: placing the adhesive layers on the plane surfaces of the open-cell foam layer, one on each plane surface; aligning the straight-of-grain lines of each of the pair of woven fabric layers, the lines directionally aligned with each other; adhering the woven fabric layers to the adhesive layers on the open-cell foam layer while maintaining the alignment of the straight-of-grain lines of the woven fabric layers such that the straight-of-grain lines of both woven fabric layers are directionally aligned when forming the lamination; and cutting the lamination into the panel; and sewing the panel together to form the element and the elements together to form the hat.