Patent Publication Number: US-2021177080-A1

Title: Novelty headwear allowing attachment of decorative elements

Description:
TECHNICAL FIELD 
     The present disclosure relates generally to headwear, and more specifically to a cap that allows removable decorative items to be attached at different location on the cap to change the appearance of the cap. 
     BACKGROUND 
     Embroidered patches and decorative accessories such as golf ball markers for golf themed caps are popular elements of sports caps or hats and have been used for many years. Most embroidered caps have permanent decorative elements that are sewn or otherwise adhered to the exterior of the cap. This requires the purchase multiple caps in order to wear caps of different decorations. 
     Certain solutions have been proposed to increase the flexibility of a single cap to show different decorative elements. For example, various pins may be offered that may be stuck into a cap. However, such pins are often limited in size and may damage the cap if they are moved often. Tactical caps use Velcro as an attachment mechanism to provide a user with the ability to change patches. However, tactical caps are tied to the placement of a Velcro footprint pre-sewn onto the cap for attaching the decorative items. Thus, the appearance of the cap is fixed by the placement of the Velcro footprint(s) as decorative items may only be attached to the areas with the Velcro footprint. 
     There is a need for a cap that includes the ability to place decorative items in different locations. There is also a need for headwear having a pocket for a utility belt for holding different decorative icons. There is also a need for headwear that includes the ability to make removable decorative items appear to be permanently attached to the headwear. 
     SUMMARY 
     One disclosed example is a headwear system. The headwear system includes a fabric head covering having a securing mechanism on an interior surface of the fabric. A utility belt is inserted in the securing mechanism. The utility belt has a magnet. A decorative element having a ferrous material is provided. The decorative element is attached to an exterior area of the head covering by the magnet of the utility belt, corresponding to a location of the magnet. 
     Another disclosed example is a cap with a selectable appearance. The cap includes a fabric material having an exterior surface and an interior surface. A utility belt having a plurality of magnets arranged in a pattern is provided. The utility belt is attached to the interior surface under a side and a front of the cap. A first decorative element, having a ferrous material, is attachable on the exterior surface of the fabric material on the side or the front of the cap via any one of the plurality of magnets 
     The above summary is not intended to represent each embodiment or every aspect of the present disclosure. Rather, the foregoing summary merely provides an example of some of the novel aspects and features set forth herein. The above features and advantages, and other features and advantages of the present disclosure, will be readily apparent from the following detailed description of representative embodiments and modes for carrying out the present invention, when taken in connection with the accompanying drawings and the appended claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure will be better understood from the following description of exemplary embodiments together with reference to the accompanying drawings, in which: 
         FIG. 1A  is a perspective side view of an example cap with attached decorative items; 
         FIG. 1B  is a front view of the example cap in  FIG. 1A ; 
         FIG. 2A  is a front perspective, partial cutaway view of the example cap in  FIG. 1A  with an inserted utility belt to hold decorative items; 
         FIG. 2B  is a side perspective, partial cutaway view of the example cap in  FIG. 1A ; 
         FIG. 2C  is a front partial cutaway view of an example cap in  FIG. 1A  with the inserted utility belt to hold decorative items; 
         FIG. 2D  is a back partial cutaway view of an example cap in  FIG. 1A  with the inserted utility belt to hold decorative items; 
         FIG. 3  is a front view of the utility belt in  FIG. 1 ; 
         FIG. 4A  shows different sectional views of the main component of the utility belt in  FIGS. 2A-2D ; 
         FIG. 4B  shows different sectional views of the side components of the utility belt in  FIGS. 2A-2D ; 
         FIG. 5A  is a close-up view of an example decorative item from  FIG. 1A ; 
         FIG. 5B  is a sectional view of the example decorative item in  FIG. 5A ; 
         FIG. 5C  is a layer cutaway view of the example decorative item in  FIG. 5A ; 
         FIG. 6A  is a perspective view of the example cap in  FIG. 1A  with different decorative elements to create a different appearance; 
         FIG. 6B  is a perspective view of the example cap in  FIG. 1A  with different decorative elements than those in  FIG. 6B  to create yet another different appearance; 
         FIG. 7A  is a back perspective view of the example cap in  FIG. 6A  with the addition of another decorative element to change the appearance of the cap  100 ; 
         FIG. 7B  is a front perspective view of the example cap in  FIG. 7A  with the decorative elements rearranged to change the appearance of the cap  100 ; and 
         FIG. 7C  is a front perspective view of the example cap in  FIG. 7B  with the decorative elements rearranged to change the appearance of the cap  100 . 
     
    
    
     The present disclosure is susceptible to various modifications and alternative forms. Some representative embodiments have been shown by way of example in the drawings and will be described in detail herein. It should be understood, however, that the invention is not intended to be limited to the particular forms disclosed. Rather, the disclosure is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims. 
     DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS 
     The present inventions can be embodied in many different forms. Representative embodiments are shown in the drawings, and will herein be described in detail. The present disclosure is an example or illustration of the principles of the present disclosure, and is not intended to limit the broad aspects of the disclosure to the embodiments illustrated. To that extent, elements and limitations that are disclosed, for example, in the Abstract, Summary, and Detailed Description sections, but not explicitly set forth in the claims, should not be incorporated into the claims, singly or collectively, by implication, inference, or otherwise. For purposes of the present detailed description, unless specifically disclaimed, the singular includes the plural and vice versa; and the word “including” means “including without limitation.” Moreover, words of approximation, such as “about,” “almost,” “substantially,” “approximately,” and the like, can be used herein to mean “at,” “near,” or “nearly at,” or “within 3-5% of,” or “within acceptable manufacturing tolerances,” or any logical combination thereof, for example. 
     The present disclosure relates to a method of changing the external appearance of headwear via replaceable decorative elements attached to the headwear through magnetic force. A magnetic utility belt is inserted into an interior securing mechanism of a cap. The utility belt provides structure and a method of attachment for decorative elements such as patches, markers, and other exterior elements. Exterior elements such as patches and markers remain in position on the headwear through magnetic attraction between the magnetic utility belt and ferrous elements on the decorative element. 
     The present decorative system for a cap or other headwear includes an interior utility belt on the interior of the cap and external decorative elements that may be affixed to the front or sides of the cap. Magnetic force joins the decorative elements to the utility belt through the material of the cap. To create the utility belt, magnets are placed on a neoprene foam material and encased with heat applied material such as vinyl. External decorative elements such as patches are created by adhering a flexible ferrous material between fabric layers. The external decorative elements may therefore be placed in different areas of the cap backed by the utility belt. 
     The example interchangeable decoration system allows the display of multiple surface embellishments on a cap. The attachment system is an improvement to existing cap decorations via its flexible magnetic canvas upon which users may remove and replace decorative elements of different designs, shapes, and locations. Embellishments remain in place through magnetic force along a template of strong magnets. The foam utility belt insert has multiple magnets in an array to allow attachment of decorative elements on a larger surface area in comparison to traditional embroidered headwear and tactical hats. The utility belt is stabilized by an interior pouch in the cap. Decorative elements may be removed and interchanged from the cap by the user. 
       FIGS. 1A-1B  show perspective views of a decorative headwear article which may be a cap  100 . Specifically,  FIG. 1A  is a perspective side view of an example cap  100  with attached decorative items and  FIG. 1B  is a front view of the example cap  100  in  FIG. 1A . As will be explained the appearance of the cap  100  may be altered via the placement of the decorative items and the attachment of different decorative items. 
     The cap  100  includes decorative items that may be placed in different exterior surfaces of the cap  100 . The cap  100  includes a brim  110 , and multiple triangular panels  112 . The panels  112  may be constructed from any appropriate natural or synthetic fabric material such as twill. The panels  112  are each sewn to each other via seams on respective lateral angled sides. A side between the lateral angled sides forms a generally circular open end  120  defined by a bottom rim  122 . An interior semi-circular sweat band backs the rim  122  at the open end  120 . The ends of the rim  122  on the opposite end of the brim  110  are attached to straps  126  and  128 . In this example, the strap  126  has holes and the strap  128  has matching pins that allow them to be attached each other in an adjustable fashion in order to adjust the circumference of the open end  120  to accommodate different head sizes. A proximal end of each of the panels  112  are joined at a button  124  that defines the top of the cap  110 . The brim  110  is attached to a front end of the cap  100  as defined by the panels  112  in the front. 
     Different decorative items may be attached to the exterior of the cap  100  as defined by the panels  112 . For example,  FIGS. 1A-1B  show four decorative items  140 ,  142 ,  144  and  146  attached to the cap  100 . The decorative items  140 ,  142 ,  144  and  146  may be of any desirable size or shape. The decorative items  140 ,  142 ,  144  and  146  are ferrous-infused and attached to the front and sides of the cap  100  as a user desires and retained by magnetic force. Although four decorative items are shown in  FIG. 1A , it is to be understood that any number of decorative items may be affixed to the cap  100 . The decorative items give the appearance that they are permanent parts of the cap  100 . In this example, the decorative item  140  is attached in the center of the front of the cap  100  above the brim  110 . The decorative items  142  and  144  are attached on the panel  112  on one side of the cap  100 . The decorative item  146  is attached on the panel  112  on the opposite side of the cap  100  as shown in  FIG. 1B . As will be explained below, the decorative items, such as the decorative items  140 ,  142 ,  144 , and  146 , may be fixed in place but may also be replaced or moved around to alter the appearance of the cap  100 . 
       FIGS. 2A-2D  show partial cutaway views of the cap  100  that show an embedded utility belt  200  that serves to fix decorative items such as decorative items  140 ,  142 ,  144 , and  146  in place as shown in  FIG. 1A .  FIG. 2A  is a front perspective, partial cutaway view of the example cap  100  in  FIG. 1A  with the inserted utility belt  200  to hold decorative items.  FIG. 2B  is a side perspective, partial cutaway view of the example cap  100 .  FIG. 2C  is a front partial cutaway view of an example cap  100  in with the inserted utility belt  200  to hold decorative items.  FIG. 2D  is a back partial cutaway view of an example cap  100  with the inserted utility belt  200  to hold decorative items. 
     A securing mechanism such as an interior pouch  210  is formed behind the front panels  112  of the cap  100 . The pouch  210  may be part of the sweat band  122  and thus encircles the sides and the front of the cap  100 . Other structures may hold the utility belt  200  such as a belt loop structure. The bottom edge of the pouch  210  is attached to the front panels  112 . The utility belt  200  is inserted between the interior pouch  210  and the interior of the panels  112 . The utility belt  200  is thus held in place by the interior pouch  210  and the interior surfaces of the panels  112 . Other devices such as interior loops may be used to secure the utility belt  200 . 
     The utility belt  200  slides into the interior of the cap  100  and rests in the pouch  210  that is connected to the sweat band  123  of the cap  100 . From a rear view, the bottom foam layer of the utility belt  200  faces the user&#39;s forehead. Thus, the utility belt  200  sits behind the front of the cap  100  and wraps around each side. The utility belt  200  thus is concealed by the panels  112 . Decorative items such as the decorative items  140 ,  142 ,  144 , and  146  that have ferrous material magnetically adhere to the utility belt  200  through magnetic force. 
       FIG. 3  is a front view of the utility belt  200 . As may be seen in  FIGS. 2A-2D  and  FIG. 3 , the utility belt  200  includes a center piece  220  and two side pieces  222  and  224 . In this example, the center piece  220  rests behind the front of the cap  100  and has a greater height than the side pieces  222  and  224  that each extend at the level of the sweatband  123 . The side pieces  222  and  224  are rectangular shaped in this example. The decorative items may be attached to exterior of the cap in any exterior area that is backed by any of the pieces  220 ,  222  and  224  of the utility belt  200 . 
       FIG. 4A  are sectional views of the center piece  220  of the utility belt  200 .  FIG. 4B  are sectional exploded view of the components of the side piece  222 . In this example, the center piece  220  of the utility belt  200  is shown in  FIG. 4A  broken up in the different layers. The center piece  220  includes a backing layer  230 , a magnet array  232  and a sealing layer  234 . The backing layer  230  in this example is a pliant material such as fabric, foam or neoprene. The backing layer  230  is closest to the head of the wearer, and is thicker than other fabric layers to provide a cushion for the utility belt  200 . The magnet array layer  232  is attached to the backing layer  230  and supports a series of magnets  236 . The magnet array layer  232  in this example, includes a foam material  238  having the magnets  236  placed in a pattern to accept a variety of shapes and sizes of decorative elements. The sealing layer  234  in this example, is a plastic sealant (e.g. heat transfer vinyl) that permanently holds the magnets  236  in their designated array pattern on the foam material  238  of the magnet array layer  232 , when the sealing layer  234  is heat treated. When heated, the sealing layer  234  is caused to adhere to the foam  238 . In this example, the magnets  236  are 1/16″ thick and the neoprene material of the backing layer  230  is of similar thickness. In this example, the magnets  236  may be between ⅛″ and 1/16″ thick. 
     Similarly, as shown in  FIG. 4B , the side piece  222  includes a backing layer  250 , a magnet array  252  and a sealing layer  254 . The backing layer  250  in this example is a pliant material such as fabric, foam or neoprene. The backing layer  250  is closest to the head of the wearer, and is thicker than other fabric layers to provide a cushion for the utility belt  200 . The magnet array layer  252  is attached to the backing layer  250  and supports different magnets  256 . The magnet array layer  252  in this example, includes a foam material  258  having magnets  256  placed in a pattern to accept a variety of shapes and sizes of decorative elements. The sealing layer  254  in this example, is a plastic sealant (e.g. heat transfer vinyl) that permanently holds the magnets  256  in their designated array pattern on the foam  258  of the magnet array layer  252 . The materials of the backing layer  250 , magnet array layer  252 , and the sealing layer  254  are similar to their counterparts in the center piece  220 . The side piece  224  is of identical construction and materials as the side piece  222  shown in  FIG. 4B . In this example, the layers of the side pieces  222  and  224  are fabricated in one piece with the layers of the center piece  220 . 
       FIGS. 5A-5C  detail the sections of a decorative item such as the decorative element  140 .  FIG. 5A  is a close up view of the decorative item  140 .  FIG. 5B  is a cross section view of the decorative item  140 .  FIG. 5C  is a sectional partial cutaway view of the layers of the decorative item  140 . The decorative element  140  in this example is a decorative ferrous patch. The other elements  142 ,  144 , and  146  in  FIG. 1A  are smaller in size, but have similar layers as will be described below in relation to the decorative item  140 . The decorative item  140  is constructed having a bottom layer  510 , a flexible ferrous sheet  520  in the same shape in the middle, and a decorated front layer  530 . The bottom layer  510  is constructed of fabric or similar material is lightweight and thin to minimize the magnetic pull required for the ferrous decorative object to remain in place on the exterior of the cap  100 . The front layer  530  may be decorated with embroidery, digital print, screen print, or other decoration method. The layer  510 , ferrous sheet  520 , and front layer  530  are held together either by the front embellishment (e.g. heat transfer vinyl), bonding fabric, or other fabric adhesive. Other methods and mechanisms may be used to join the layers of the decorative element  140 . 
     The system incorporates strong magnets permanently affixed in a pattern inside a foam insert  238  in the magnet array layers  232  of the utility belt  200 . The decorative elements contain a critical mass of ferrous material in order to adhere to the magnets  236  or  256  under the exterior of the cap  100  through the weight of the fabric of the cap  100 . Different sized decorative elements may be attached to like sized magnets in the utility belt  200 . For example, as shown in  FIG. 2A , the decorative element  142  is attached to the position of one of the magnets  256  embedded in the side piece  222  of the utility belt  200 . Alternatively, larger decorative elements may be attached to multiple magnets in the utility belt  200 . For example, the decorative element  140  is a larger patch shape than the smaller decorative element  142  and as shown in  FIG. 2C-2D , is attached to four magnets  236  in the center piece  220  of the utility belt  200 . The decorative elements are secured in position and retained by magnetic pull of the strong magnets encased in the interior utility belt  200 . The utility belt  200  is concealed on the inside of the cap  100  and out of view. 
     Machinery ensures positive placement of the magnets  236  and  256  in a predetermined array on the foam layers  238  and  258  in  FIGS. 4A-4B . The magnetic array layers  232  and  252  allows decorative items such as patches to be displayed in centered and planned positions according to the size and shape of the patch. The platen in manufacturing equipment accounts for the location of the magnets  236  and  256  on the utility belt  200  to avoid reaching levels of heat that may impact the strength of magnetic pull during the production process. 
     By utilizing the above described cap  100  and utility belt  200 , patches and other ferrous elements will adhere to the front and sides of a hat and are held in place by the force of magnetic attraction with a sufficient strength so as to remain attached despite the cap material construction and normal movement while wearing the cap  100 . Decorative patches remain stabilized in place through magnetic attraction until a user pulls the decorative item from the cap  100  at a force strong enough to clear the magnetic field. Thus, a user may change the appearance of the cap  100  by replacing some or all of the decorative elements, moving the location of some or all of the decorative elements, or adding or taking off some or all of the decorative elements. 
     Different sets of decorative elements may be provided to allow the cap  100  to be used for branding or other purposes. For example, a golf company may provide the cap  100  where the decorative patch  140  at the front of the cap  100  in  FIG. 1A-1B  is the logo of the company. The other decorative elements  142 ,  144  and  146  may be graphics of golf related items such as a golf ball, a golf club and a pin flag. 
     The appearance of the cap  100  may be changed by providing another set of decorative elements with a different common theme. Further, the appearance of the cap  100  may also be changed by changing the locations of the decorative elements. For example, the cap  100  with the decorative elements  142 ,  144 , and  146  may be altered with the addition of another decorative element. Alternatively, the appearance of the cap  100  with the decorative elements  142 ,  144 , and  146  may be altered with another patch that replaces the decorative logo patch  140 . 
       FIG. 6A  shows a perspective view of the cap  100  with a different set of decorative elements  600 ,  602 , and  604 . Each of the decorative elements  600 ,  602 , and  604  have ferrous material and are attached to the utility belt  200  to replace other decorative elements such as the decorative elements  140 ,  142 ,  144  and  146 . The decorative elements  600 ,  602 , and  604  all relate to a football theme. In this example, the element  600  is a logo patch and attached to the front of the cap  100 . The decorative elements  602  and  604  represent different items (e.g., a pennant and a football) that relate to the general theme. Thus, the appearance of the cap  100  in  FIG. 6A  differs from the cap in  FIGS. 1-2 . 
       FIG. 6B  shows a perspective view of the cap  100  with a different appearance, as the decorative elements  600 ,  602 , and  604  have been replaced with elements  620 ,  622 , and  624 . Each of the decorative elements  620 ,  622 , and  624 , have ferrous material and are attached to the utility belt  200 . The cap  100  now has a different appearance than that shown in  FIG. 6A  or  FIG. 1A  as the decorative elements  620 ,  622 , and  624  relate to another theme such as baseball. 
     As explained above, the decorative elements may be moved, replaced or other decorative elements may be added to the cap  100  to change the appearance of the cap  100 .  FIG. 7A  is a back perspective view of the cap  100 , where the decorative item  622  has been removed and the decorative item  624  has been moved to the position where the decorative item  622  was attached. Further, an additional decorative element  630  has been added to a location next to the decorative item  624 . 
       FIG. 7B  is a front perspective view of the cap  100  with a different appearance created by rearranging the decorative elements  620 ,  624  and  630  in  FIG. 7A . In this example, the decorative element  620  (the logo patch) has been moved to the side of the cap  100 . The decorative elements  624  and  630  have been attached to the front of the cap  100 . 
       FIG. 7C  is a front perspective view of the cap  100  with another different appearance created by rearranging the locations of the decorative elements  620 ,  624  and  630  in  FIG. 7B . In this example, the decorative element  620  (the logo patch) has been moved to the front of the cap  100 . The decorative element  624  has also been attached to the front of the cap  100 , while the decorative element  630  remains at the side of the cap  100 . 
     The utility belt  200  may be used with a known cap such as a baseball cap and allow decorative elements to be attached to the exterior of the cap. For example, the utility belt  200  may be inserted in a sweat band on the interior of a normal cap. Alternatively, the utility belt  200  may be attached to the interior of a normal cap by means of connection mechanisms such as straps, tape or similar devices. 
     The terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting of the invention. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. Furthermore, to the extent that the terms “including,” “includes,” “having,” “has,” “with,” or variants thereof, are used in either the detailed description and/or the claims, such terms are intended to be inclusive in a manner similar to the term “comprising.” 
     The term fabric, as used herein, is to be construed in its broadest sense of any thin, expansive, flexible, or supple material of the type typically utilized in the construction of apparel and decorative arts such as embroidery. 
     The term vinyl applies to heat transfer vinyl, decorative vinyl, and other flexible, thin, expansive materials such as plastic sheet material. 
     The term foam applies to neoprene, rubber, silicone, felt, and other flexible cast materials. 
     The ferrous material may be a flexible sheet or infused layer of fabric, rubber, or flexible metal. 
     Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art. Furthermore, terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art, and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein. 
     While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not limitation. Although the invention has been illustrated and described with respect to one or more implementations, equivalent alterations and modifications will occur or be known to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In addition, while a particular feature of the invention may have been disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be desired and advantageous for any given or particular application. Thus, the breadth and scope of the present invention should not be limited by any of the above described embodiments. Rather, the scope of the invention should be defined in accordance with the following claims and their equivalents.