Abstract:
A hat-cord assembly, kit, and method for manufacturing same provides users with a hat construction and a braided or weaved length of cord fastened thereto. The hat construction comprises a looped hat band or foliage ring, which band or ring comprises at least one aperture structure extending therethrough. The length of cord is preferably braided to provide both a decorative effect and an ample cord source when attached to the hat band or foliage ring. The cord preferably comprises thermally-liquefiable material and has opposed primary cord ends, which ends are insertable through the aperture structure and are thermally-liquefiable for respectively liquefying the primary cord ends at the aperture structure. The liquefied primary cord ends are thermally-solidifiable for fastening the primary cord ends to the hat band at the aperture structure.

Description:
PRIOR HISTORY 
       [0001]    This application is a Continuation-in-Part (CIP) patent application claiming the benefit of pending U.S. patent application Ser. No. 12/799,135, filed in the United States Patent and Trademark Office on 19 Apr. 2010, the specifications of which are hereby incorporated into this specification in their entirety by reference thereto. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention generally relates to a (boonie) hat assembly, and more particularly, to a hat-cord combination for providing users with a decorative length of cord readily available and wearable upon the user&#39;s hat. 
         [0004]    2. Description of Prior Art 
         [0005]    U.S. Pat. No. 2,117,937 (&#39;937 patent), which issued to Brownell, discloses a Knife Sheath. The &#39;937 patent describes a sheath like body providing a pocket for the blade of a knife, a tongue formed on the body and rising therefrom, said tongue on the body and rising therefrom, said tongue having spaced parallel slots extending longitudinally therein, means including a loop extending through the slots for adjustment with respect to the tongue for receiving and gripping the handle of the knife, and a substantially arrowhead shaped flap formed on the means and having spaced parallel slots therein to receive the belt of the wearer of the sheath for slidably securing the flap to the belt, and means for detachably securing the flap to the tongue. 
         [0006]    U.S. Pat. No. 4,803,745 (&#39;745 patent), which issued to Izquierdo, discloses a Survival Knife Sheath. The &#39;745 patent describes a knife sheath including a rear side defining an upwardly opening receptacle portion for downwardly receiving therein the blade of a survival knife and a front side defining a pair of side-by-side upwardly opening compartments with one of the compartments having a plurality of aerial flares stored therein and the other compartment defining an aerial flare supporting compartment in which the base end of one of the aerial flares may be removably retentatively supported. 
         [0007]    The knife sheath of the &#39;745 patent further defines a firing pin bore disposed immediately beneath and opening upward into the aforementioned other compartment and containing an upwardly spring biased firing pin therein for impact with a center primer portion of the base end of aerial flare retained in position thereabove: The sheath also includes an exteriorly slidably mounted trigger member operably connected to firing pin through a slot formed in the sheath and upon which downward manual digital pressure may be applied to downwardly retract the firing pin from an associated aerial flare for subsequent release and impact engagement with the flare primer. 
         [0008]    U.S. Pat. No. 4,805,818 (118 patent), which issued to Harrison, discloses a Knife Sheath and Tool Device. The &#39;818 patent describes a knife sheath device comprising a gripping or cutting type of tool such as a pair of pliers or wire cutters. The device includes a sheath pivotally mounted upon a back plate with the back plate and sheath cooperating to form and operate the tool. Portions of the tool are formed or attached to the sheath and also to the back plate, and the tool is operated by pivoting the sheath in relation to the back plate. 
         [0009]    U.S. Pat. No. 4,805,819 (&#39;819 patent), which issued to Collins, discloses a Sheath for a Retractable Knife. The &#39;819 patent describe a sheath for housing a retractable knife both in its retracted or unretracted state provided with a pair of pockets, one adapted to receive the knife blade and a second adapted to receive the knife when the blade is housed within its handle, and additionally capable of being folded into a more compact form when housing a retracted knife. 
         [0010]    U.S. Pat. No. 5,009,348 (&#39;348 patent), which issued to Derkatz, discloses a Knife Sheath of Tough Flexible Material. The &#39;348 patent describes a knife sheath comprising a back wall, a front wall attached at its periphery to said back wall to form a knife-receiving pouch, and a pair of laterally spaced slits in said front wall for receiving a wearer&#39;s belt, said slits being offset in the longitudinal direction, whereby when the wearer&#39;s belt is passed through said offset slits said pouch sits at a forward angle on the wearer&#39;s belt and snugly located on the wearer&#39;s hip and tucked in the belt. 
         [0011]    U.S. Pat. No. 6,840,416, (&#39;416 patent), which issued to Aberman, describes a Knife Sheath. The &#39;416 patent describes a sheath for carrying a knife or blade comprising a scabbard attached to a carrying strap forming a loop through which a carrying junction such as a belt may be passed. The axis of the loop is generally aligned with a transverse axis perpendicular to an axis of gravity. The length of the scabbard includes a longitudinal axis generally angled with respect to the axis of gravity. The mouth of the scabbard is further angled with regard to the transverse axis. Each of the foregoing alignments allows a user to more easily and efficiently insert and remove a blade into the scabbard while carrying the sheath. The sheath is also provided with an inner shell disposed inside the scabbard, the inner shell having a plurality of lengthwise linear ridges for gripping the blade inside the shell. 
         [0012]    United States Patent Application No. 2008/0250652, which was authored by Fellhoelter, describes a knife and sheath that includes a spring element as part of the handle with a pin that engages a slot in the sheath so as to lock the knife and sheath together. The knife and sheath are unlocked by biasing the spring element towards the center line of the knife, thereby disengaging the pin from the slot. 
         [0013]    It is noted that in addition to knives, hats and other gear are commonly used in for outdoor activities. For example, a boonie hat, also known as a bush hat, is a form of wide-brim hat commonly used by military forces. Its design is similar to a bucket hat or fishing hat but with a stiffer brim. Often a fabric tape band of “branch loops” or “foliage ring” is sewn around the crown of the hat. This “foliage ring” is meant to hold additional vegetation or similar matter for camouflage purposes. 
         [0014]    To those with extensive experience in outdoor and primitive camping scenarios, it should become apparent that there are situations that invariably arise in which one requires or could greatly benefit from additional cordage, but which cordage is not readily available with the supplies on hand. As a boonie hat may be readily worn in such situations, it becomes apparent that the extra cordage could also be attached to such a hat the hat via the foliage ring, thus having cordage available whenever the need arises. 
         [0015]    After exhaustive development, it was found that weaving or braiding a cord and attaching it to a boonie type hat via apertures formed in the foliage ring afforded several additional feet of cordage with no interference to the hat. This additional cordage was invaluable for situations in which tent or tarp cords need to be replaced, emergency fishing line is needed (e.g. the cordage exemplified in this application comprise thinner strands which can be separated for this purpose), clothesline for drying, tying lean to shelters, and securing gear, for example. 
         [0016]    It will be seen from an inspection of the prior art juxtaposed adjacent the foregoing conceptual bases that the prior art perceives a need for a hat-cord combination for providing users with a readily available source of cord, easily carried or worn around the crown of one&#39;s head and ornamentally or decoratively applied to a boonie hat or similar other head wear. 
       SUMMARY OF THE INVENTION 
       [0017]    Accordingly, it is a primary object of the present invention to provide certain means for carrying additional cordage attached to a boonie hat in a compact and easily accessible manner. The purpose of the additional cordage being attached to the hat allows the carrier to have approximately 44 feet (on a 25 to 27-inch hat band) of cordage available for both emergency and non-emergency situations. The unique weaving-braiding process of the cordage allows for various lengths of cordage based on the hat size being used. 
         [0018]    To achieve these and other readily apparent objectives, the present invention essentially provides a hat-cord assembly or combination, a hat-cord assembly kit, and a method for manufacturing same such that users thereof are provided a (boonie type) hat and a readily accessible length of cord. The hat-cord combination according to the present invention thus comprises, in combination a hat assembly and a (braided) length or lengths of cord. 
         [0019]    The hat assembly comprises a hat construction having a crown portion and a hat band or foliage ring, which foliage ring is periodically stitched widthwise along its length to portions of the crown portion of the hat thereby providing branch loops around which the cord length may be braided. The hat band further comprises at least one aperture structure extending therethrough, preferably at the posterior portion of the band, for providing an anchor aperture to which a cord terminus may be anchored. 
         [0020]    The length of cord preferably comprises thermally-liquefiable material and has opposed primary cord ends, which primary cord ends are insertable through the aperture structure and are thermally-liquefiable for respectively liquefying the primary cord ends at the aperture structure. The liquefied primary cord ends are thermally-solidifiable for fastening or anchoring the primary cord ends to the band-based apertures (preferably outfitted with grommets). The hat-cord assembly or combination according to the present invention thus provides users with a hat construction in combination with end-fastened length(s) of cord. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0021]    Other features of my invention will become more evident from a consideration of the following brief description of patent drawings: 
           [0022]      FIG. 1  is a top, anterior perspective view of the hat-cord combination assembly according to the present invention. 
           [0023]      FIG. 2  is a top perspective view of a basic prior art (boonie) hat assembly outfitted with a foliage ring or hat band, which foliage ring comprises a series of undulating loops. 
           [0024]      FIG. 3  is an enlarged fragmentary depiction of a posterior portion of the hat assembly otherwise depicted in  FIG. 2 , showing a pair of grommets inserted into the terminal ends of the foliage ring, which terminal ends are stitched to a posterior seam of a crown portion of the hat assembly. 
           [0025]      FIG. 4  is a depiction of a grommet application device and a hat assembly, the grommet application device for applying grommets to the hat assembly substantially as depicted. 
           [0026]      FIG. 5  is an enlarged fragmentary depiction of a posterior portion of the hat assembly according to the present invention depicting a first cord attaching arrangement with heat or thermal energy being directed into cord ends to heat-melt or thermally liquefy the cord ends at the grommet structures thereof. 
           [0027]      FIG. 5(   a ) is an enlarged, fragmentary sectional view of a first cord-to-band, grommet-based junction site showing two cord strands inserted through a band aperture, one of which extends under the band and one of which is being heat melted or thermally liquefied. 
           [0028]      FIG. 5(   b ) is an enlarged, fragmentary sectional view of a second cord-to-band, grommet-based junction site showing two cord strands inserted through a band-based, grommet-lined aperture, one of which extends under the band, and one of which has been heat melted or thermally liquefied and thermally solidified, the latter of which has parts broken away to depict otherwise hidden structure. 
           [0029]      FIG. 5(   c ) is an enlarged, fragmentary sectional edge view of the cord-to-band, grommet-based junction site otherwise depicted in  FIG. 5(   b ) showing a cord strand inserted through a band-based, grommet-lined aperture and having been thermally liquefied with thermal energy being directed out of the liquefied material for solidifying the liquefied material at the cord end and anchoring the cord end to the hat band. 
           [0030]      FIG. 6  is a depiction of three cords, two of which cords are coiled at the lower end thereof and oppose a folded or undulated central cord. 
           [0031]      FIG. 7  is a depiction of a braided cord assembly with parts broken away to show an inner folded cord structure according to the present invention. 
           [0032]      FIG. 8  is a depiction of a braided cord assembly according to the present invention. 
           [0033]      FIG. 9  is a first sequential enlarged fragmentary depiction of a posterior portion of the hat assembly showing (1) a first cord with melted terminus being directed inwardly at an upper grommet-lined aperture such that the melted terminus is exterior to the band, and (2) a second cord with melted terminus being directed outwardly at a lower grommet-lined aperture such that the melted terminus is interior to the band. 
           [0034]      FIG. 10  is a second sequential enlarged fragmentary depiction of a posterior portion of the hat assembly showing otherwise depicted in  FIG. 9  showing the first and second cords being looped and braided together about a looped section of the hat band or foliage ring of the hat assembly. 
           [0035]      FIG. 11  is a diagrammatic depiction of a preferred cord-to-band arrangement showing a preferred method for braiding two cords together about the hat band or foliage ring of the hat assembly. 
           [0036]      FIG. 12  is a top, posterior perspective view of the hat-cord combination assembly according to the present invention. 
           [0037]      FIG. 13  is an enlarged, fragmentary depiction of a section of band length having a series of grommet-lined apertures formed therein with the left most grommet-lined aperture having a cord section length extending therethrough, which cord section length comprises a melted globule terminus and is outfitted with a C-shaped crimp clamp. 
           [0038]      FIG. 13(   a ) is an enlarged, fragmentary depiction of a section of cord length outfitted with a C-shaped crimp clamp. 
           [0039]      FIG. 13(   b ) is an enlarged transverse cross-sectional view of the cord length outfitted with a C-shaped crimp clamp as sectioned from  FIG. 13(   a ). 
           [0040]      FIG. 14  is an enlarged fragmentary diagrammatic sectional side view depiction of a melted globule cord terminus extending through a grommet-lined band-based aperture with C-shaped crimp clamp. 
           [0041]      FIG. 14(   a ) is an enlarged fragmentary sectional view of a portion of the structures otherwise depicted in  FIG. 14  to more clearly show structural relationships. 
           [0042]      FIG. 15  is a top perspective view of a hat-cord combination kit according to the present invention showing a braided cord, a coiled cord length, and a (boonie type) hat element in (translucent) packaging. 
           [0043]      FIG. 15(   a ) is a end elevational view of the hat-cord combination kit otherwise depicted in  FIG. 15  showing the coiled cord length and hat element in (translucent) packaging. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0044]    Referring now to the drawings with more specificity, the present invention essentially provides a hat-cord combination  10  or utility gear assembly for providing users with a hat-cord combination  10  essentially comprising a hat construction as at  11  and an ornamentally or decoratively braided length of cord as at  12 . The ornamentally braided cord  12  is attached or fastened to the hat construction  11  in a unique manner. Before being braided, the cord  12  is typically provided in various cord lengths  15  as specified by the user. 
         [0045]    From a comparative inspection of the figures, the reader may note that the unbraided cord lengths  15  may be assembled such that an inner folded cord length  16  may be enveloped by an outer braided cord length  17 , and together the length  16  and the length  17  may cooperably yield the ornamentally braided length of cord as at  12 . The essential notion being addressed is to maximize the overall length of cord otherwise fastenable or outfittable upon the hat construction  11  for exemplary use in outdoor or survival type scenarios. 
         [0046]    The preferred material construction of the cord  12  is that of so-called parachute cord otherwise known as paracord or 550 cord, which cord typically has a nylon or polymeric component. In this regard, it is noted that a key feature of the cord  12  (regardless of brand name or provider) is that it preferably comprises thermally-liquefiable material, which material once liquefied into a globule, may be re-solidified into an irregularly shaped globular anchor  14  to “weld” or anchor the cord ends  13  of the cord  12  to a hat band or foliage ring (as at  18 ) of the hat construction  11 . 
         [0047]    Notably, “nylon” is a generic designation for a family of synthetic polymeric materials known generically as polyamides first produced on in the 1930&#39;s by Wallace Carothers of E. I. du Pont de Nemours and Company (DuPont). As used in this application, the essential feature of the material is its thermoplastic attributes. In other words, a key aspect of the cord  15  is that the polymeric material liquefies when heated (i.e. thermally energized as at  100 ) and freezes to a hardened state when cooled (i.e. thermally de-energized as at  101 ) sufficiently. 
         [0048]      FIG. 5(   a ) attempts to depict the cord end  13  being softened into a liquefied globular state as at  14 .  FIGS. 5(   b ) and  5 ( c ) attempt to depict the hardened, frozen, or solidified anchor  19 , which anchor  19  comprises a width or diameter sufficient to anchor the cord end  13  to the hat band or foliage ring  18  of the hat construction  11  via the aperture structure formed therein. In this regard,  FIGS. 5(   b ) and  5 ( c ) depict apertures as at  20  formed in the hat band or foliage ring  18  of the hat construction  11 , which apertures  20  extend through the thickness of the hat band or foliage ring  18 . Preferably, the apertures  20  of the hat band or foliage ring  18  are outfitted with eyelets or grommets  21  or similar other relatively rigid structures for preventing the anchors  19  from passing through the apertures  20 .  FIG. 4  is a depiction of a grommet application device  31  and a hat assembly or hat construction  11  depicting a generic a grommet application device  31  applying eyelets or grommets  21  to the hat assembly  11  substantially as depicted. 
         [0049]    In this regard, it is contemplated that C-shaped crimp clamps or “C-clamps”  29  may also be outfitted upon the cord  15  adjacent the aperture structure  20  for enhancing the fastened attachment of the cord ends  13  to the hat band  18 . It should be noted that the crimp clamps or C-clamps  29  are preferably formed from a rigid material and comprise an outer diameter  120  greater in magnitude than the inner diameter  121  of the grommets  21  for preventing the clamps  29  from passing through the grommets  21 . Further, the clamps  29  preferably comprise inwardly radiating pointed structures as at  30 , which structures or protrusions  30  pinch or crimp the cord  15  radially inward substantially as shown in  FIG. 13(   b ). The protrusions  30  are believed to enhance the anchored attachment of the cord ends  13  to the apertures  20  of the band  18 . 
         [0050]    It is contemplated that the hat construction  11  may be formed from either flexible or rigid materials and that the braided cord  12  may be severed from the hat band or foliage ring  18  of the hat construction  11  (e.g. by way of a bladed element (not specifically shown). The length of cord  15  or lengths of cord are preferably attached to the hat construction  11  by way of the hat band or foliage ring  18 , which ring or band  18  is periodically stitched as at  102  to the crown  22  of the hat construction widthwise across the ring or band  18  for forming periodic loops  23 . The lengths of cord may then be wrapped around the band loops  23  and braided together as comparatively depicted in  FIGS. 6-11 . 
         [0051]    Referencing  FIG. 11  it will be seen that a first cord at  24  primarily extends along the posterior or inward side of the hat band  18  but for forward loops  25  through which loops  25  a second cord  26  passes. The second cord  26  loops together the loops  25  via loops  27  substantially as shown. Cord  24  passes downward as at  110 , then forward or outward as at  111 , then rightward as at  112  then rearward or inward as at  113 , then upward as at  114 , then forward as at  115 , then rightward as at  116 , then rearward or inward downward as at  117 , and then downward as at  118 . The second cord  26  essentially is directed downward as at  119  and upward as at  120  via loops  27  to link to together with cord  24  via loops  25 . 
         [0052]    While the above description contains much specificity, this specificity should not be construed as limitations on the scope of the invention, but rather as an exemplification of the invention. For example, it is contemplated that the present invention essentially provides a hat-cord combination or assembly comprising a hat construction as at  11  and at least one length of cord as at  15  or at least one braided length of cord as at  12 . 
         [0053]    The hat construction  11  preferably comprises a crown portion as at  22  and a hat band as at  18 . The hat band or foliage ring  18  preferably comprises a series of band loops as at  23 , and at least one, but preferably two pair of apertures as at  20 . The band loops  23  are periodically spaced about the circumference of the crown portion  22  and enable cord length to be fed through the loops between the band  18  and the crown portion intermediate stitching  102  for maximizing the overall length of the cord  15 . Each cord-receiving aperture extends through the thickness  103  of the hat band  18  adjacent a terminal end  30  of the hat band  18 . 
         [0054]    Each length of cord  15  is preferably constructed from or comprises thermally-liquefiable material and has opposed primary cord ends as at  13 . The primary cord ends  13  are insertable through the aperture structures  20  formed through the hat band  18  and are thermally-liquefiable for respectively liquefying the primary cord ends  13  at the aperture structure(s)  20 . The liquefied primary cord ends  13  as at globules  14  are thermally-solidifiable for fastening the primary cord ends  13  to the hat band  18  at the aperture structure(s)  20  via solidified globule anchors  19 . The hat-cord assembly  10  thus provides users with a hat construction  11  with a readily available, end-fastened length of cord  15 . 
         [0055]    The aperture structure of the hat band  18  may be defined by at least one pair of apertures, but preferably two pair of apertures, one pair being located at each band terminus with an upper aperture and a lower aperture. Such an arrangement enables effective attachment of at least two cords (of varying colors) so as to enhance the visual appearance of the braided arrangement. The primary cord ends  13  are attachable to the hat band  18  at the pair(s) of apertures  20 . 
         [0056]    Stated another way, the hat band  18  according to the present invention preferably comprises a first band end (as at  30 ), a second band end (as at  3 ), and a band length (e.g. 25-27 inches) intermediate said first and second band ends  30 . The aperture structure(s) may be preferably defined by at least two pairs of apertures, whereby the first pair of apertures are adjacent the first band end and a second pair of apertures are adjacent the second band end. The length or lengths of cord  15  are extendable along the band length intermediate the first and second band ends  30  in any number of ways, but preferably as described and shown in this application. 
         [0057]    For example, the length(s) of cord may preferably be braided for maximizing the effective cord length extendable along the band length intermediate the first and second band ends  30 . A plurality of cord lengths may preferably be inter-braided for further maximizing the effective cord length extendable along the band length intermediate the first and second band ends  30 . The cord length(s) preferably comprise a series of cord ends, which ends are thermally-liquefiable and thermally solidifiable for fastening the plurality of cord lengths to the hat construction  11  at the aperture structure(s). 
         [0058]    The apertures  20  may preferably be outfitted with a grommet structure as at  21 , which grommet structure is believed to enhance anchor attachment of the thermally solidifiable primary cord ends  13  or anchors  19 . Further, each cord end  13  may be preferably outfitted with a crimp clamp  29  at the anchor site for enhancing anchor attachment of the thermally solidifiable primary cord ends  13  or anchors  19 . 
         [0059]    Still further, the foregoing specifications are believed to support kit-related aspects and certain methodology for assembling a hat-cord combination or utility gear assembly. In this last regard, it is contemplated that the hat-cord kit according to the present invention, as provided in a package  35 , may well provided users with a hat construction  11  outfittable with a length of cord  15 . 
         [0060]    The method for assembling a hat-cord combination according to the present invention may be said to comprise the steps of: forming a hat construction as at  11 , wherein the hat construction  11  comprises a crown-based hat band  18 . The hat band  18  preferably comprises at least one aperture structure extending therethrough (preferably outfitted with grommets  21 ). 
         [0061]    At least one length of cord  15  may then be provided, which length of cord  15  preferably comprises thermally-liquefiable material and has opposed primary cord ends. The primary cord ends may be extended through the aperture structure of the hat construction whereafter thermal energy may be directed into the primary cord ends thereby liquefying the thermally-liquefiable material at the primary cord ends. 
         [0062]    The thermally liquefied material may then be solidified into globule like anchors  19  for fastening each length of cord to the hat band or foliage ring  18  at the aperture structure(s). The hat band  18  may preferably comprise a series of band loops, about and through which at least one length of cord may be cooperaably intertwined for outfitting the hat construction  11  with added length of cord. At least one outer braided length of cord may further envelope at least one inner length of cord before extending the primary cord ends through the aperture structure of the hat band  18 . The method may further comprise the step of forming a hat construction  11  having at least one grommet-lined aperture. In other words, the method may comprise the step of forming at least one grommet-outfitted aperture structure as generally depicted in  FIG. 4 . As previously set forth, it is contemplated that the grommet structure  21  may well enhance anchor attachment of the thermally solidifiable primary cord ends  13  at anchors  19 . Further, the crimp clamps  29  when attached to the cord ends  13  may also operate to enhance anchor attachment. 
         [0063]    Accordingly, although the invention has been described by reference to certain preferred and alternative embodiments, and certain methodology, it is not intended that the novel disclosures herein presented be limited thereby, but that modifications thereof are intended to be included as falling within the broad scope and spirit of the foregoing disclosure, the following claims and the appended drawings.