Method of forming a raised three-dimensional decorative image on a fabric product and cap made thereby

1. An article of headwear having an image printed directly thereon and embossed in relief to define a raised, three-dimensional decorative ornamental image comprising:

an article of headwear comprising a dome-shaped crown which is configured and dimensioned to be removably receivable directly upon the head of a wearer, said crown having an outer surface, an inner surface and a bottom arcuate edge defining a lower opening projecting into said dome-shaped crown;

wherein a portion of said crown comprises at least one fabric panel which has an outer surface, an inner surface and a bottom arcuate edge coincident with said outer surface, said inner surface and said bottom arcuate edge of said crown, respectively;

wherein said at least one fabric panel and, in turn, said portion of said crown has a, non-embroidered, decorative ornamental image imprinted directly on said outer surface of said fabric panel via dye sublimation so as to be coincident therewith, the resulting dye sublimated, non-embroidered, decorative ornamental image comprising a plurality of colors;

wherein a portion of said fabric panel and, in turn, said non-embroidered, decorative, ornamental image is embossed in relief to define an outwardly-extending, convexly-shaped, embossed portion of said fabric panel and, in turn, of said decorative non-embroidered, ornamental image;

wherein another portion of said fabric panel and, in turn, said non-embroidered decorative, ornamental image is non-embossed to define a relatively flat, non-embossed portion of said fabric panel and, in turn, said non-embroidered, decorative, ornamental image;

wherein said embossed portion of said fabric panel and, in turn, said non-embroidered, decorative, ornamental image has a convexly-shaped, raised profile and contour disposed above said relatively flat, non-embossed portion of said fabric panel and, in turn, of said non-embroidered decorative ornamental image, that varies in height with respect to said fabric panel and, in turn, said relatively flat, non-embossed portion of said non-embroidered, decorative, ornamental image to thereby create a three-dimensional effect to said dye-sublimated, non-embroidered, decorative ornamental image coincident with said outer surface of said fabric panel and, in turn, a portion of said crown of said article of headwear;

wherein said article of headwear comprises a baseball cap style hat including said dome-shaped crown, and a bill attached to, and extending outwardly from, said bottom arcuate edge of a front portion of said crown, and wherein said fabric panel is incorporated into at least said front portion of said crown of said cap;

wherein said embossed portion of said non-embroidered decorative ornamental image comprises a plurality of embossed portions and said plurality of embossed portions of said non-embroidered, decorative ornamental image is in alignment with at least a portion of said decorative ornamental image on said outer surface of said fabric panel to create a three-dimensional sculptured effect in relief, relative to said non-embroidered, decorative ornamental image on said fabric panel;

wherein said fabric panel is made of a synthetic fabric selected from the group consisting of a knit polyester fabric, an acrylic fabric and a microfiber fabric; and

wherein said fabric panel additionally includes a fabric lining and a foam backing, with said foam backing being disposed between said fabric panel and said fabric lining.

2. The headwear according to claim 1 , wherein:

said non-embroidered, decorative ornamental image is a member selected from the group consisting of designs, characters, cartoon images, lettering, text, logos, shapes, slogans, images, scenes, photographs, vignettes and a combination thereof.

3. The headwear according to claim 1 , wherein:

said embossed portions of said non-embroidered, decorative ornamental image comprises a plurality of spaced-apart embossed portions.