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

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.

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.

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.