Knit Cap With Multiple Layer Construction and Process of Making Same

1. In a multi-layer knitted cap formed of a knitted tubular piece having an initial unfolded length and initial opposite open ends, the tubular piece also including a first tightly knitted gathered area equally spaced between the initial opposite open ends, the improvement comprising: a second tightly knitted gathered area located between the first tightly knitted area and one of the initial opposite ends, said second tightly knitted area being located nearer to the first tightly knitted area than to the one initial opposite end; a third tightly knitted gathered area located between the first tightly knitted area and the other one of the initial opposite ends, said third tightly knitted area being symmetrically and oppositely located with said second tightly knitted area relative to the first tightly knitted area; a first fold line defined by the first tightly knitted area and along which the entirety of the initial unfolded length is folded upon itself, thereby defining a once-folded length of the tubular piece in which said second and third tightly knitted areas are located in general registry with each other and the initial opposite ends are also located in general registry with each other; a second fold line located between the registry of the initial opposite ends and the registry of said second and third tightly knitted areas and along which the entirety of the once-folded length is folded upon itself, thereby defining a twice-folded length of the tubular piece in which said second and third tightly knitted areas are still located in general registry with each other; a closed end defined by the initial opposite ends and said first fold line joined in general registry therein; an open end spaced from said closed end and peripherally bounded by said second fold line; first and second inner layers folded on themselves about said second fold line; first and second outer layers folded on themselves and on said first and second inner layers with said first outer layer forming the outside surface of said cap and said second outer layer forming the inside surface of said cap; and whereby said second tightly knitted area extends circumferentially about said first outer layer and said third tightly knitted area extends circumferentially about said second outer layer and in general registry with said second tightly knitted area.

2. The improvement according to claim 1 and further including a fourth tightly knitted gathered area adjacently spaced from said second tightly knitted area intermediate said second tightly knitted area and the one initial opposite end, a fifth tightly knitted gathered area adjacently spaced from said third tightly knitted area intermediate said third tightly knitted area and the other initial opposite end and being symmetrically and oppositely located with said fourth tightly knitted area relative to the first tightly knitted area; wherein, when said cap is in said once folded length, said fourth and said fifth tightly knitted areas are located in general registry with each other; wherein said second fold line is located between the registry of said second and third tightly knitted areas and the registry of said fourth and fifth tightly knitted areas; and whereby said fourth tightly knitted area extends circumferentially about said first inner layer, said fifth tightly knitted area extends circumferentially about said second inner layer, and said second, third, fourth, and fifth tightly knitted areas are in general registry with each other.

3. The improvement according to claim 1 wherein the portion of said cap between the registry of said second and third tightly knitted areas and said open end is folded upwardly toward said closed end using the registry of the second and third tightly knitted areas as a fold line, whereby a cuff is provided around said open end.

4. The improvement according to claim 1 wherein the overlapping panels between said closed end and the registry of said second and third tightly knitted areas includes means defining face openings therein, whereby said cap is adapted to extend over the face of a wearer and the registry of said second and third tightly knitted areas is adapted to be located beneath the chin of the wearer.

5. The method of constructing a knit cap comprising the steps of, continuously knitting an elongated tubular member, periodically knitting a gathered, tighter stitched area at spaced intervals along the length of said continuous tubular member, a first of such gathered areas being knit in an area equal distance between the ends of said tubular piece, second and third gathered areas being knit in an area generally equally located between one of the open ends of said tubular piece and said first area, said second and third areas being knit generally equally located between said first area and said first open end and being relatively spaced from each other, fourth and fifth gathered areas being knit in an area between said first area and the second open end of said continuous piece and on the opposite side of said first area from said second and third areas, said fourth and fifth areas being knit generally equally located between said first area and said second open end and said fourth and fifth areas being relatively spaced from each other, folding said continuous tubular member on itself with said first area as a fold line, and bringing said second and third gathered areas into overlapping registry with respective ones of said fourth and fifth gathered areas, making a second fold in said continuous piece by folding the already folded piece on itself using a point equally located between said second and third and fourth and fifth gathered areas as the second fold line and bringing said second, third, fourth and fifth areas into overlapping registry, bringing the central area into registry with the original open ends of said tubular piece, and stitching said original open ends and said first gathered area together to close one end of said twice-folded tubular member.