Patent Publication Number: US-2023148697-A1

Title: Headwear Articles That Are Selectively Convertible To A Mask Configuration

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. application Ser. No. 17/500,225, filed Oct. 13, 2021, which claims priority to and the benefit of the filing date of the following patent applications: U.S. Provisional Patent Application No. 63/091,016, filed Oct. 13, 2020; and U.S. Provisional Patent Application No. 63/180,974, filed Apr. 28, 2021. Each of these applications is incorporated herein by reference in its entirety. 
    
    
     FIELD 
     This application relates generally to articles of headwear (e.g., caps) that are selectively convertible from a headwear configuration to a mask configuration. 
     BACKGROUND 
     The COVID-19 Pandemic has made it necessary for most individuals to carry masks and other personal protective equipment anytime they leave their residence. However, it is challenging to keep up with the location of such masks at all times, and individuals are prone to inadvertently leave their masks at home. Further, even when individuals remember their masks, it is inconvenient to travel with masks in pockets, and it is difficult to repeatedly adjust the positioning of masks to complete various activities, such as eating or drinking. There is a need for products that address one or more of these deficiencies. 
     SUMMARY 
     Described herein, in various aspects, is an article of headwear that is convertible between a headwear configuration and a mask configuration. The headwear can comprise a crown for covering at least a portion of a head of a wearer, a visor, and at least one mask support element coupled to the crown. The crown can have a rear portion and a front portion that cooperate to define a circumference of the crown, and the visor can be attached to the front portion of the crown. From the headwear configuration, at least a portion of the rear portion of the crown can be collapsible into the front portion of the crown to position the headwear in the mask configuration. In the mask configuration, the at least one mask support element can be configured to secure the headwear over a portion of a face of the wearer. 
     Methods of using the disclosed headwear articles are also described. 
     Additional advantages of the invention will be set forth in part in the description that follows, and in part will be obvious from the description, or may be learned by practice of the invention. The advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       These and other features of the preferred embodiments of the invention will become more apparent in the detailed description in which reference is made to the appended drawings wherein: 
         FIG.  1    is a front perspective view of an exemplary headwear article as disclosed herein. 
         FIG.  2    is a schematic side view of an exemplary headwear article as disclosed herein, with the headwear article shown in a headwear configuration. 
         FIG.  3 A  is a schematic side view of the headwear article of  FIG.  2   , with the headwear article shown in a mask configuration.  FIG.  3 B  is a schematic side view of the headwear article of  FIG.  3 A , with the headwear article positioned over the face of a wearer.  FIG.  3 C  is a schematic side view of the headwear article of  FIG.  3 B , showing pivoting of the visor relative to the position depicted in  FIG.  3 B . 
         FIG.  4    depicts an exemplary headwear article (e.g., cap) having loops that extend from the crown of the headwear article to support the headwear article in the mask configuration over the face of the wearer. 
         FIG.  5    depicts an exemplary headwear article (e.g., cap) having a band that extends from the crown of the headwear article to support the headwear article in the mask configuration over the face of the wearer. 
         FIG.  6    depicts an exemplary mask support element in a stowed position as disclosed herein. 
         FIG.  7 A  depicts an exemplary mask support element in a stowed position as disclosed herein.  FIG.  7 B  is a close-up view depicting an exemplary fastener for coupling the mask support element of  FIG.  7 A  to a headwear article as disclosed herein.  FIG.  7 C  is a close-up view depicting stitching that secures the fastener of  FIG.  7 B  to the headwear article. 
         FIGS.  8 A- 8 C  are various views of a wearer using a headwear article (e.g., cap) with the mask support element of  FIGS.  7 A- 7 C  in a stowed position. 
         FIGS.  9 A- 9 C  are various views of a wearer wearing a headwear article (e.g., cap) in a mask configuration, in which the mask support element of  FIGS.  7 A- 7 C  is in a use position that supports the headwear article over the face of the wearer. 
         FIG.  10    depicts an exemplary lanyard for use as a mask support element as disclosed herein. 
         FIG.  11    is a rear view of an exemplary crown having a slot that receives a filter. 
     
    
    
     DETAILED DESCRIPTION 
     The disclosed system and method may be understood more readily by reference to the following detailed description of particular embodiments and the examples included therein and to the Figures and their previous and following description. 
     It is to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of the present invention which will be limited only by the appended claims. 
     It must be noted that as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise. Thus, for example, reference to “a support element” includes one or more of such support elements, and so forth. 
     “Optional” or “optionally” means that the subsequently described event, circumstance, or material may or may not occur or be present, and that the description includes instances where the event, circumstance, or material occurs or is present and instances where it does not occur or is not present. 
     Ranges may be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, also specifically contemplated and considered disclosed is the range from the one particular value and/or to the other particular value unless the context specifically indicates otherwise. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another, specifically contemplated embodiment that should be considered disclosed unless the context specifically indicates otherwise. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint unless the context specifically indicates otherwise. Finally, it should be understood that all of the individual values and sub-ranges of values contained within an explicitly disclosed range are also specifically contemplated and should be considered disclosed unless the context specifically indicates otherwise. The foregoing applies regardless of whether in particular cases some or all of these embodiments are explicitly disclosed. 
     Optionally, in some aspects, when values are approximated by use of the antecedents “about,” “substantially,” “approximately,” or “generally,” it is contemplated that values within up to 15%, up to 10%, up to 5%, or up to 1% (above or below) of the particularly stated value or characteristic can be included within the scope of those aspects. 
     Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of skill in the art to which the disclosed apparatus, system, and method belong. Although any apparatus, systems, and methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present apparatus, system, and method, the particularly useful methods, devices, systems, and materials are as described. 
     Throughout the description and claims of this specification, the word “comprise” and variations of the word, such as “comprising” and “comprises,” means “including but not limited to,” and is not intended to exclude, for example, other additives, components, integers or steps. In particular, in methods stated as comprising one or more steps or operations it is specifically contemplated that each step comprises what is listed (unless that step includes a limiting term such as “consisting of”), meaning that each step is not intended to exclude, for example, other additives, components, integers or steps that are not listed in the step. 
     In various aspects, and with reference to  FIGS.  1 - 9 C , disclosed herein is an article of headwear  10  that is convertible between a headwear configuration and a mask configuration. As shown the headwear  10  can optionally be provided in the form of a cap, such as a baseball cap. In one aspect, the headwear  10  can comprise a crown  20  for covering at least a portion of a head of a wearer. As shown in  FIGS.  2 - 3 C , the crown  20  can have a rear portion  26  and a front portion  24  that cooperate to define a circumference  41  of the crown. In another aspect, the headwear  10  can comprise a visor  31  attached to the front portion  24  of the crown  20 . In exemplary aspects, the visor  31  can have a conventional visor board configuration, such as, for example, a visor with a semi-rigid polymer visor board sandwiched between textile elements. 
     In further aspects, it is contemplated that crown  20  can form a generally hemispherical covering for a head of a wearer, with the visor  31  extending outward in a generally horizontal direction from the crown  20  to shade the face and eyes of the wearer. Optionally, the materials forming crown  20  can extend entirely around a circumference of the head to provide headwear  10  with the appearance of a fitted baseball cap that accommodates an individual with specific head dimensions. 
     In exemplary aspects, the crown  20  can comprise a plurality of panels  21  that are attached together along abutting sides. Optionally, crown  20  can comprise six panels, such as, for example, two front panels, two side panels, and two rear panels. The various panels  21  can define an exterior surface  22  and an opposite interior surface (not shown). Optionally, in exemplary aspects, the crown  20  can further comprise a button  28  where the panels meet at the top of the crown. Optionally, in further exemplary aspects, the crown  20  can further comprise at least one aperture  49 , with each aperture being formed in a respective panel  21  to improve the transfer of air through the crown. 
     In use, and with reference to  FIGS.  2 - 3 C , when starting from the headwear configuration (in which the headwear is positioned over, or configured for positioning over, the head of a wearer), at least a portion of the rear portion  26  of the crown  20  is collapsible into the front portion  24  of the crown to position the headwear in the mask configuration. In exemplary aspects, it is contemplated that the rear portion  26  can be displaced by applying force to the portion of the exterior surface  22  defined by the rear portion of the crown  20 . In these aspects, it is contemplated that the force can be applied in the general direction of the front portion  24  of the crown  20  (or the visor  31 ), for example, relative to displacement axis  15  ( FIG.  1   ). It is contemplated that the mechanical connection between the visor  31  and the front portion  24  of the crown  20  can provide sufficient structural support to the front portion  24  of the crown that the front portion of the crown will generally retain its shape while the rear portion  26  is folded inwardly and collapsed into the front portion. In use, it is contemplated that the force can be applied manually, by hand or by pressing the exterior surface of the rear portion of the headwear  10  against a portion of the body (e.g., head) of the wearer or another structure or surface. Optionally, the force can be applied while the wearer holds the visor (without directly holding the crown). Optionally, in exemplary aspects, the interior of the front portion  24  of the crown can comprise a fastener that is configured to engage a complementary fastener of the interior of the rear portion  26  of the crown to secure the crown in the mask configuration. 
     In contrast to conventional headwear (e.g., cap) designs, the disclosed headwear  10  can comprise at least one mask support element  50  coupled to the crown. When the headwear  10  is in the mask configuration, the at least one mask support element can be configured to secure the headwear over a portion of a face of the wearer. 
     Optionally, in exemplary aspects, and as shown in  FIGS.  1 - 4   , the at least one mask support element  50  can comprise a plurality of mask support elements, such as, for example, first and second mask support elements that are configured to engage portions of respective ears of the wearer. In some aspects, the plurality of mask support elements  50  can comprise first and second loops that extend outwardly from the crown that, in the mask configuration, are configured for placement over respective ears of the wearer. In these aspects, it is contemplated that the loops can comprise elastic material, such as for example, rubber, which can optionally be surrounded by padding or other soft material to improve user comfort. Optionally, it is contemplated that the first and second loops can extend through respective apertures  49  that are positioned on opposing right and left sides of the crown  20 , with each loop being secured within the interior of the crown. Additionally, or alternatively, it is contemplated that one or more of the mask support elements  50  can be secured to the exterior surface  22  of the crown, for example, by sewing or by fastener (e.g., a snap attachment). More generally, it is contemplated that the mask support elements  50  can be coupled to the crown in any conventional manner that permits movement and/or adjustment of the mask support elements  50  as disclosed herein. 
     Optionally, in exemplary aspects, and as shown in  FIG.  5   , the at least one mask support element  50  can comprise at least one band that forms a continuous loop that extends outwardly from and between opposing sides of the crown. In these aspects, it is contemplated that the band can comprise elastic material, such as for example, rubber, which can optionally be surrounded by padding or other soft material to improve user comfort. Optionally, it is contemplated that the band can extend through apertures  49  that are positioned on opposing right and left sides of the crown  20 , with the band being secured within the interior of the crown. Alternatively, it is contemplated that the band can have ends that are secured to the exterior surface of the crown, for example, by sewing or by fastener (e.g., a snap attachment). More generally, it is contemplated that the band can be coupled to the crown in any suitable fashion that permits movement and/or adjustment of the band as disclosed herein. In further aspects, rather than providing a band that forms a continuous loop, it is contemplated that the at least one mask support element can comprise two separate bands (extending from opposing sides of the crown) that can be selectively tied together to secure the crown against the face of the wearer. 
     Optionally, in further exemplary aspects, the at least one mask support element  50  can be configured to be selectively moved (by the wearer) about and between a stowed position ( FIG.  6   ) and a use position ( FIG.  5   ). In some aspects, when in the stowed position, the at least one mask support element  50  (e.g., a band or strap) can at least partially rest across or over a portion of the headwear article. For example, in some aspects, and as shown in  FIG.  6   , when in the stowed position, the at least one mask support element  50  can rest across a portion of the front portion  24  of the crown and/or the visor  31 . In these aspects, it is contemplated that the at least one mask support element  50  can be pivotally coupled to the crown, thereby permitting selective pivotal movement about and between the stowed position and a use position in which the at least one mask support element extends behind the head of the wearer. Optionally, in some aspects, from the stowed position, the at least one mask support element  50  can be lifted over the crown portion to reach the use position. During or after movement of the at least one mask support element  50  to the use position, the rear portion  26  of the crown can be displaced into the front portion  24  of the crown. In other aspects, it is contemplated that in the stowed position, the at least one mask support element can rest or be positioned over a portion of the rear portion  26  of the crown. In these aspects, it is contemplated that from the stowed position, the displacement of the rear portion  26  of the crown into the front portion  24  of the crown can place the at least one mask support element  50  in the use position. Optionally, in various aspects, it is contemplated that the crown and/or the visor can comprise a fastener that is configured to retain the at least one mask support element in the stowed position. 
     An exemplary embodiment of the at least one mask support element  50  is shown in  FIGS.  7 A- 9 C . In various aspects, the at least one mask support element  50  can comprise a band  52  (e.g., strap, cord, lanyard, etc.) as further disclosed herein. As shown, the at least one mask support element  50  can further comprise first and second fasteners  56   a,    56   b  positioned on respective opposing sides of the crown. In exemplary aspects, the first and second fasteners  56   a,    56   b  can be secured to the crown such that the fasteners are accessible from (and extend outwardly from) the exterior surface of the crown. In exemplary aspects, and as shown in  FIG.  7 C , it is contemplated that one or more of the first and second fasteners  56   a,    56   b  can be secured to the crown using stitching  58  that passes through a thickness of the crown from an interior of the crown. Optionally, in these aspects, it is contemplated that the stitching  58 , in addition to passing through the crown structure, can pass through at least a portion of a sweatband or other annular structure that forms the inner circumference of the headwear article. 
     In use, the first and second fasteners  56   a,    56   b  can be configured to couple to respective portions of the band. Although specific examples of the first and second fasteners  56   a,    56   b  are described below, it is contemplated that any fastener configuration that is capable of securely coupling a band to a headwear article as disclosed herein can be used. Exemplary fasteners include buttons, hook-and-look fasteners, snaps, stitching, adhesives, clamps, clasps, pins, hooks, combinations thereof, and the like. 
     Optionally, the band  52  can define a plurality of openings  54  spaced apart along a length of the band. In some aspects, the plurality of openings  54  can be consistently spaced along substantially the entire length of the band. Alternatively, it is contemplated that the plurality of openings can be formed along only a portion(s) of the length of the band. In exemplary aspects, at least one of the first fastener  56   a  or the second fastener  56   b  can comprise a button (or projection) that is configured to be removably received within an opening  54  of the plurality of openings of the band to couple the band to the crown at a selected location along the length of the band. Optionally, in some aspects, it is contemplated that the first fastener  56   a  can permanently secure the band to the crown, while the second fastener  56   b  can be configured for receipt within an opening of the band. In these aspects, it is contemplated that the first fastener  56   a  can comprise stitching or other structure/material that permanently secures the band to a first side of the crown, while the second fastener  56   b  can comprise a button (or projection) or other fastener that non-permanently couples the band to an opposing second side of the crown, thereby permitting adjustment of the fit of the band over or around a portion of the wearer&#39;s head. 
     As shown in  FIGS.  7 A- 9 C , in some aspects, the first and second fasteners  56   a,    56   b  can optionally comprise first and second buttons that are configured to be removably received within respective openings  54  of the plurality of openings of the band to couple the band to the crown at selected locations along the length of the band. In these aspects, it is contemplated that with the band coupled to the crown at both the first and second buttons, the band  52  can have a first portion  55   b  that extends between the first and second buttons, a second portion  55   a  that extends beyond the first button (moving away from first portion  55   b ), and a third portion  55   c  that extends beyond the second button (moving away from first portion  55   b ). It is contemplated that the operative lengths of each of these portions of the band  52  can be selectively adjusted based upon the particular openings of the band through which the respective buttons extend, thereby allowing for modification of the fit when the headwear article is in the mask configuration. In particular, it is contemplated that the operative length of the first portion  55   b  (between the first and second buttons) can determine the amount of material of the band that is available for passage around the back of the head of the wearer (See  FIGS.  9 A- 9 C ). To adjust the operative length of the first portion  55   b,  the first and/or second buttons can be withdrawn from an opening of the band and passed through a different opening of the band, thereby increasing or reducing the operative length of the first portion (and loosening or tightening the fit). When in the hat configuration, it is contemplated that the band can either be removed from the buttons or pivoted to a stowed configuration in which the first portion  55   b  of the band  52  extends across the crown over the visor (See  FIGS.  8 A- 8 C ). 
     In further exemplary aspects, and as shown in  FIG.  10   , it is contemplated that the at least one mask support element  50  can comprise a lanyard or lanyard-style strap, band, or cord. In these aspects, it is contemplated that portions of the lanyard can be coupled together by a lock  60  (e.g., a bead, clamp, clip, stopper, or other releasable (optionally, spring-loaded) fastener) that has a central bore, which is configured to simultaneously receive and frictionally engage the portions of the lanyard. In use, it is contemplated that the lock  60  can be released and selectively advanced along the operative length of the lanyard and then reengage the portions of the lanyard, thereby loosening or tightening the fit of the mask over the face of the user. More particularly, it is contemplated that the lock can be advanced toward the head of the wearer to tighten the fit, while the lock can be advanced away from the head of the wearer to loosen the fit. Optionally, it is contemplated that the at least one mask support element  50  can further comprise a stop structure  62  that receives a portion of the lanyard and prevents advancement of the lock  60  beyond the stop structure. It is further contemplated that the stop structure  62  can provide a surface (or surfaces) that can be gripped by the wearer while the lock is advanced toward or away from the head of the wearer. In exemplary aspects, it is contemplated that opposing ends of the lanyard can be secured or coupled to opposing portions of the crown of the headwear article. In some aspects, it is contemplated that the opposing ends of the lanyard can be secured or coupled to opposing portions of the crown in the same manner disclosed herein with respect to other exemplary mask support elements  50 . For example, in some aspects, it is contemplated that the opposing ends of the lanyard can comprise respective fasteners that are configured to engage complementary fasteners associated with the opposing portions of the crown of the headwear article. In some aspects, it is contemplated that the lanyard can be permanently associated with the crown of the headwear article, with the lanyard being moveable about and between a stowed position (when the article is in the headwear configuration) and a use position (when the article is in the mask configuration) as disclosed herein. In still other aspects, it is contemplated that the lanyard can permanently associated with the crown and be configured for use in both the headwear and mask configurations. For example, it is contemplated that the lanyard can provide additional support to the headwear article when the article is used in the headwear configuration and permit adjustment of the fit of the article when the article is used in the mask configuration, with the lanyard extending rearwardly of the head of the wearer in both configurations. 
     In further exemplary aspects, at least a portion of the crown (in particular, at least the rear portion  26  of the crown that contacts portions of the face of the wearer) can comprise antimicrobial material, particularly anti-viral material. In exemplary aspects, it is contemplated that the antimicrobial material can comprise silver, copper, or combinations thereof. In further aspects, and as shown in  FIG.  11   , it is contemplated that the antimicrobial material can be embodied as a filter  27  that is selectively receivable within a slot  29  that is defined within the interior of the crown. 
     In still further exemplary aspects, it is contemplated that the crown can have an elastic base that is configured to conform to a circumference of a head of the wearer, thereby providing a secure fit when the headwear article is in the headwear configuration. In these aspects, when the headwear article is in the mask configuration, it is contemplated that the elastic base structure can be manually displaced from the face of the wearer to provide an opening that permits access to the face of the wearer from under the visor. In use, it is contemplated that displacement of the elastic base to form the opening can advantageously permit unobstructed access to the mouth of the wearer for purposes of eating or drinking without the need for completely exposing the face of the wearer. 
     Additionally, or alternatively, the visor  31  can be pivotally connected to the crown. For example, in the mask configuration, the visor  31  can be configured to pivot from a closed position that restricts access to the face of the wearer from under the visor to an open position that permits access to the face of the wearer from under the visor. Optionally, with reference to  FIGS.  3 B- 3 C , it is contemplated that the headwear  10  can comprise a hinge  32  that provides the pivotal connection between the visor and the crown. In further aspects, it is contemplated that the hinge  32  can cooperate with at least one stop or catch structure to permit retention of the visor in the closed or open position unless sufficient force is applied to overcome the retention force. In use, it is contemplated that movement of the visor to the open position can advantageously permit unobstructed access to the mouth of the wearer for purposes of eating or drinking without the need for completely exposing the face of the wearer. 
     In exemplary aspects, it is contemplated that the headwear articles can be provided in various sizes (e.g., men&#39;s, women&#39;s, or children&#39;s sizes). Additionally, or alternatively, it is contemplated that the headwear article can include an adjustable closure feature as is known in the art for selectively adjusting the operative size/diameter of the headwear article. 
     In further exemplary aspects, it is contemplated that the headwear articles can be provided in various styles, including for example, and without limitation, a baseball cap-style headwear article, a visor-style headwear article, and the like. Optionally, in these aspects, the headwear articles can be provided with visors of various dimensions. 
     In still further exemplary aspects, it is contemplated that the headwear articles can comprise logos and/or graphics. Optionally, in some aspects, such logos and/or graphics can be provided on a portion of the crown of the headwear article, such as, for example, on the front portion  24  of the crown. 
     In still further exemplary aspects, the crown can optionally comprise an internal storage compartment (not shown) for storing sanitized wipes or other disinfecting components or materials. 
     In use, when the mask configuration of the headwear is no longer needed or desired, the crown can be removed from the face of the wearer. Then, the crown can be expanded from the mask configuration to the headwear configuration, and the crown can be positioned over a portion of the head of the wearer. It is contemplated that the sequential conversion to and from headwear configuration to mask configuration can be repeated as many times as desired, thereby providing a convenient way to carry and keep up with a mask that serves the dual purpose of a headwear article when not in use. 
     In exemplary aspects, it is contemplated that kits can be provided for converting conventional headwear articles into headwear articles as disclosed herein, which can selectively transition between headwear and mask configurations. For example, such conversion kits can comprise at least one mask support element  50  and at least one fastener (optionally, at least two fasteners) that couples (optionally, permanently secures) the at least one mask support element  50  to the crown of the headwear article. Examples of such fasteners are further disclosed herein and include, for example, and without limitation, a quantity of thread (for sewing), a quantity of adhesive, a snap fastener, hook-and-loop fastener material, a button, a clip, a clamp, a hook, a loop, combinations thereof, or other suitable fasteners that are capable of functioning as disclosed herein. Examples of such mask support elements are further disclosed herein and include, for example, a band, a strap, a lanyard, and the like. Optionally, in some aspects, the fasteners of the kit can comprise at least one fastener configured to be associated with the crown of the headwear article and at least one fastener associated with the at least one mask support element and configured to complementarily engage the fastener(s) associated with the crown. In further aspects, it is contemplated that the disclosed kits can further comprise a manual or pamphlet having instructions for modifying the structure of the headwear article to permit conversion between a headwear configuration and a mask configuration as further disclosed herein. Such manuals or pamphlets can provide instructions concerning the locations for placement of respective fasteners, the methods for securing the respective fasteners to the headwear article, and methods for attaching, removing, and/or adjusting the mask support elements to permit conversion between the headwear and mask configurations and allow for adjustment of fit. In some aspects, it is contemplated that the kits can comprise a plurality of different types, styles, and/or colors of fasteners and/or a plurality of different types, styles, and/or colors of mask support elements to allow the wearer to customize the look and performance of the headwear article. 
     Although the foregoing invention has been described in some detail by way of illustration and example for purposes of clarity of understanding, certain changes and modifications may be practiced within the scope of the appended claims.