Patent ID: 8434166

Claim:
An article of headwear comprising: a molded support having an elongate structure that defines a first end portion and a second end portion, the molded support being flexed such that the first end portion is positioned adjacent the second end portion to define a loop with an interior area; a first material element extending around the interior area of the loop to define an aperture for receiving a head of an individual, wherein an outer edge of the first material element wraps around the molded support to define a tubular structure for receiving the molded support; and a second material element secured to the first material element and positioned adjacent the first end portion and the second end portion of the molded support, the second material element being located substantially within the interior area of the loop and the second material element extending only partially around the interior area of the loop to define a flap; wherein the first end portion and the second end portion overlap each other within the tubular structure to define an overlapped area of the molded support, and the first end portion and the second end portion have mating undulating configurations in at least a portion of the overlapped area, wherein the mating undulating configurations provide the article of headwear with adjustability for different head dimensions; wherein the molded support has a rectangular cross-section that defines a first major surface and an opposite second major surface, wherein the rectangular cross-section of the molded support is designed to have a varying orientation that includes a horizontal orientation in a forward region, a diagonal orientation in side regions, and a vertical orientation in a rearward region.