Patent Publication Number: US-7591026-B2

Title: Headwear item with associated shaping item

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to headwear and, more particularly, to a headwear item having a projecting rim/bill. 
     2. Background Art 
     Myriad headwear designs are currently offered with a forwardly projecting rim/bill. This rim/bill configuration is common to visors and baseball-style caps. 
     Baseball-style caps have become increasingly popular and stylish in many circles. Baseball-style caps are desired for their comfort as well as the function they perform in shielding a wearer&#39;s face from sun and the elements. 
     These caps are adorned in many different ways. The most common adornment is that associated with athletic teams at all professional and amateur levels. These caps are also commonly used to promote activities, events, institutions, products, etc. As a result, those businesses offering this type of headwear must generally display a wide range of products, differing in terms of type, quality and ornamentation. 
     With so many competitors in the headwear industry, it is important that displays be devised to highlight particularly the ornamentation on these caps. Further, these displays are preferably set up so that users can conveniently try on the headwear for purposes of look and feel. 
     Ideally, baseball-style caps are displayed in the same general starting state with the rim/bill slightly bowed into an inverted “U” shape. However, users often have different preferences, particularly in terms of the shape of the rim/bill. Typically, the rims/bills are made from a material that can be shaped, normally by forcibly bending the rim/bill material. One popular shape is a more squared, inverted “U” shape achieved by producing spaced bend lines extending in a fore-and-aft direction. Prospective purchasers often will shape the rim/bill to their liking at the point of purchase and check the appearance thereof by wearing the headwear. 
     The assignee herein currently offers a baseball-style cap with a highly formable rim/bill. One form of this headwear piece is shown in U.S. Pat. No. 6,076,192. 
     As noted above, it is undesirable that a point of purchase display have headwear pieces with rims/bills that are bent into different configurations. While the rims/bills are made to exhibit good shape memory, there is generally a residual deformation after the rim/bill is re-shaped. To avoid this problem, it is known to provide systems with shaping components for the rim/bill. These shaping systems come in many different forms and generally are designed to produce a fairly consistent, downwardly opening, arcuate shape for the rim/bill. 
     Generally, the shaping systems are designed either to be recovered by the purveyor of the headwear or remain with the headwear after sale. While the shaping systems are effective in maintaining rims/bills consistently in a desired starting shape, each type has some inherent drawbacks. 
     If the shaping system is designed to be recovered, the establishment that sells the headwear piece must devise a system to remove and handle the same for re-use. If the shaping systems are retained by the headwear purchasers, it is normally intended that the shaping systems will be discarded. Consequently, the shaping system becomes a single use item. As a result, the shaping systems are designed to be cheaply manufactured and, as a result, may not perform as effectively as desired. Additionally, there is an inherent inconvenience having components that must be disposed of in an appropriate manner by the ultimate consumer. 
     SUMMARY OF THE INVENTION 
     In one form, the invention is directed to a method of using wearable items. The method includes the steps of: providing a headwear item having a crown that engages a wearer&#39;s head and a rim/bill projecting angularly away from the crown; providing a second item; attaching the second item to the rim/bill; separating the second item from the rim/bill; and wearing the second item with the second item separated from the headwear item on at least one of: a) the wearer&#39;s limb or hair; or b) a clothing item worn by the wearer. 
     In one form, the step of attaching the second item to the rim/bill involves attaching the second item to the rim/bill so that the second item maintains a shape of the rim/bill. 
     In one form, the rim/bill has spaced side edges and the step of attaching the second item to the rim/bill involves engaging the rim/bill at the space side edges so that the second item causes the rim/bill to bow between the spaced side edges. 
     The step of attaching the second item to the rim/bill may involve changing a configuration of the second item to vary bowing of the rim/bill between the side edges. 
     The step of providing a second item may involve providing an elongate second item that can be reconfigured and independently maintained in a plurality of different shapes. 
     The method may further include the step of reconfiguring the second item after the second item is separated from the rim/bill. 
     In one form, the step of reconfiguring the second item involves reconfiguring the second item into a curved shape, with the step of wearing the second item involving wearing the second item after the second item is reconfigured, around a limb of the wearer. 
     The step of providing a headwear item may involve providing a headwear item with information thereon relating to a first subject matter. The step of providing a second item involve may involve providing a second item with information related to the first subject matter. 
     In one form, the step of providing a second item involves providing a second item having two elongate elements that extend between the spaced side edges of the rim/bill and a web spanning between the two elongate elements. 
     The step of providing a headwear item may further involve providing a headwear item wherein the rim/bill has a core made from expanded foam. 
     The invention is further directed to the combination of a headwear item and a second item. The headwear item has a crown to engage a wearer&#39;s head and a rim/bill projecting away from the crown. The second item is attached to the rim/bill. The second item is separable from the rim/bill and wearable by a user apart from the headwear piece on at least one of: a) a user&#39;s limb or hair; or b) a clothing item worn by a wearer. 
     In one form, the rim/bill has spaced side edges and with the second item attached to the rim/bill, the second item engages the spaced side edges and causes the rim/bill to bow between the spaced side edges. 
     In one form, with the second item attached to the rim/bill, the second item maintains a shape of the rim/bill. 
     The second item may have a changeable configuration such that bowing of the rim/bill between the spaced side edges can be selectively changed. 
     In one form, the second item is elongate and can be reconfigured and independently maintained in a plurality of different shapes. 
     The second item may be reconfigurable into a curved shape that is wearable as a bracelet or anklet. 
     In one form, the second item has U-shaped ends within which the side edges nest with the second item attached to the rim/bill. 
     In one form, there is information on the headwear item related to a first subject matter and there is information on the second item that relates to the first subject matter. 
     The second item may consist of two elongate elements with a web spanning between the elongate elements. 
     In one form, the rim/bill has spaced side edges and the two elongate elements extend fully between the spaced side edges. 
     In one form, the two elongate elements each has spaced ends which are U-shaped and in which the spaced side edges of the rim/bill nest. 
     The rim/bill may have a core made from expanded foam. 
     In one form, the expanded foam is in a sheet form. 
     The invention is further directed to the combination of a headwear item having a crown to engage a wearer&#39;s head and a rim/bill projecting away from the crown, and a second item attached to the rim/bill. The second item is reconfigurable and independently maintainable in a plurality of different shapes. The rim/bill has spaced edges. The second item engages the rim/bill and in first and second different configurations is capable of maintaining the rim/bill bowed in first and second different shapes. 
     The second item may be fully separable from the headwear item. 
     In one form, the second item has a length and a substantially uniform width. 
     In one form, substantially the entire width engages the rim/bill substantially fully between the spaced side edges. 
     In one form, the second item has U-shaped ends within which the spaced side edges of the rim/bill nest. 
     In one form, there is information on the headwear item related to a first subject matter and there is information on the second item that relates to the first subject matter. 
     In one form, the second item has two elongate elements with a web spanning between the elongate elements. 
     In one form, the crown has a core made from expanded foam. 
     The expanded foam may be in a sheet form. 
     In one form, the second item is separable from the headwear item and is wearable on at least one of: a) the wearer&#39;s limb or hair; or b) a clothing item worn by the wearer. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic representation of the inventive combination of a headwear item with a rim/bill projecting from a crown, and a second item attachable to the rim/bill and separable therefrom to be used apart from the rim/bill; 
         FIG. 2  is a perspective view of one form of headwear item, as in  FIG. 1  and in the form of a baseball-style cap, with the second item attached to the rim/bill thereon; 
         FIG. 3  is an enlarged, cross-sectional view of the rim/bill along lines  3 - 3  of  FIG. 2 ; 
         FIG. 4  is a fragmentary, front elevation view of the rim/bill in  FIG. 2  with the second item thereon and maintaining the rim/bill in a first bowed shape; 
         FIG. 5  is a view as in  FIG. 4  wherein the second item is reconfigured to maintain the rim/bill in a second bowed shape that is different than that in  FIG. 4 ; 
         FIG. 6  is an enlarged, cross-sectional view of the second item taken along lines  6 - 6  of  FIG. 2 ; 
         FIG. 7  is an enlarged, perspective view of a clip that is attached to a free end of the second item, with the clip configured preparatory to assembly; 
         FIG. 8  is an enlarged, side elevation view of the clip in  FIG. 7 ; 
         FIG. 9  is a view as in  FIGS. 4 and 5  wherein the second item has been reconfigured to a more curved shape to be separately worn by a user; 
         FIG. 10  is a fragmentary perspective view of a user&#39;s arm with the second item in the  FIG. 9  configuration worn thereon in the form of a bracelet; 
         FIG. 11  is a fragmentary, elevation view of a user&#39;s leg with the second item in the  FIG. 9  configuration worn thereon as an anklet; 
         FIG. 12  is a schematic representation of the second item being worn on any limb of a user; 
         FIG. 13  is a schematic representation as in  FIG. 12  wherein the second item is worn on the user&#39;s hair; 
         FIG. 14  is a schematic representation as in  FIGS. 12 and 13  wherein the second item is worn on a clothing item on the user; 
         FIG. 15  is a schematic representation of the second item having a body with a fixed length between U-shaped ends; 
         FIG. 16  is a schematic representation as in  FIG. 15  of a modified form of the second item, wherein the second item has an adjustable length body between the ends thereof; 
         FIG. 17  is a view, as in  FIG. 2 , of a headwear item in the form of visor; and 
         FIG. 18  is a flow diagram representation of a method of using wearable items, according to the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE DRAWINGS 
     In  FIG. 1 , a headwear item, according to the present invention, is shown at  10  and is design to be worn by a user in a first manner. The headwear item  10  may have virtually any configuration to be usable with the invention, so long as the headwear item  10  has a crown  12  that engages a wearer&#39;s head and a rim/bill  14  projecting angularly away from the crown  12 . A second item  16  is provided in combination with the headwear item  10  and is attachable to the rim/bill  14 . The second item  16  is separable from the headwear item  10  and is usable to be worn by a user in any of a number of different manners, different that the above-noted first manner, as hereinafter described. 
     Specific forms of the headwear item  10  and second item  16  are shown in  FIGS. 2-11 . The headwear item  10  depicted is in the form of a baseball-style cap with an inverted, cup-shaped configuration for the crown  12 . The rim/bill  14  projects angularly away from the crown  12  at the front region thereof. 
     In this embodiment, the crown  12  is made from a plurality of triangularly-shaped gores  18  with matched edges  20  joined and maintained together by lines of stitching  22 . 
     The rim/bill  14  may be made from virtually a limitless number of different materials and in many different manners. Typically, and in this case, the rim/bill  14  has a bowed shape between spaced side edges  24 ,  26 . In a normal, relaxed state, the bow of the rim/bill  14  produces an inverted, curved, “U” shape between the side edges  24 ,  26 . 
     Regardless of the construction of the rim/bill  14 , it is desirable, as it is with all baseball-style caps, that the rim/bill  14  be reshapeable. This may be done by creasing the rim/bill  14  or by forcibly compressing it between the sides to cause the bowing to change to thereby produce different shapes. 
     One rim/bill construction that is particularly suitable for the present invention is that shown in U.S. Pat. No. 6,076,192, commonly assigned herewith. The disclosure in that patent is incorporated herein by reference. Generally, as shown in  FIG. 3  herein, the rim/bill  14  in U.S. Pat. No. 6,076,192 consists of a core layer  28  that is made from expanded foam material. As described in that patent, one exemplary composition is expanded, closed cell, polyvinyl chloride. The core layer  28  is formed as a sheet corresponding to the shape of the rim/bill  14  as viewed from a plan perspective. A skin layer  30  overlies the outside of the core layer  28 . The core and skin layers  28 ,  30  are sandwiched between upper and lower fabric sheets  32 ,  34 , respectively. 
     This particular rim/bill construction lends itself to reconfiguration of the rim/bill  14 . That is, the bowing of the rim/bill  14  between the side edges  24 ,  26  can be readily varied without a significant amount of compressive force application thereto upon the edges  24 ,  26 . 
     According to the invention, the second item  16  is usable to maintain the rim/bill  14  in different selected shapes. More specifically, it is preferred that the second item  16  be configured to change the particular bowed shape of the rim/bill  14 . 
     The second item  16  has an elongate body  36  with spaced ends  38 ,  40 . Two elongate wire elements  42 ,  44  extend between the ends  38 ,  40 . The wire elements  42 ,  44  are bendable and made from a material that can be reconfigured and independently maintained in virtually a limitless number of different selected shapes with the second item separated both from the first item and a user and without any external force applied to the second item. 
     A layer  46 , as from cloth, surrounds the elongate wire elements  42 ,  44  so as to define a web  48  therebetween. More particularly, as shown clearly in  FIG. 6 , the cloth layer  46  is wrapped around the wire elements  42 ,  44 , either partially or fully along the length thereof, and has ends  50 ,  52  doubled back under the web  48 . Lines of stitching  54 ,  56  are respectively formed through the web  48  and cloth end  50 , and web  48  and cloth end  52  so that spaced sleeves  58 ,  60  are formed by the cloth layer  46  respectively around the wire elements  42 ,  44 . 
     A V-shaped clip  62  is crimped at each of the ends  38 ,  40 . The clips  62  produce a neat appearance and have tangs  64  spaced along the width W thereof so that the clips  62  firmly grip the cloth layer  46  at the ends of  38 ,  40  of the body  36 , to maintain the elongate wire elements  42 ,  44  spaced apart a predetermined distance. Through this arrangement, the web  48  is lightly stretched between the wire elements  42 ,  44  along substantially the entire length of the elongate body  36 . At the same time, the clips  62  produce a neat appearance at the ends  38 ,  40 . Consequently, the body  36  has a substantially uniform width WI, corresponding approximately to the width W for the clip  62 , between opposite edges  66 ,  68  on the body  36 . 
     The ends  38 ,  40  of the body  36  are return bent to define U “shapes” thereat forming receptacles  70 ,  72 , opening generally towards each other. 
     The second item  16  can be attached to the rim/bill  14  in a number of different manners. As one example, the second item  16 , between the ends  38 ,  40 , can be pre-formed with a bowed shape corresponding to that desired for the rim/bill  14 . The bottom surface  74  of the second item  16  can then be placed facially against an upwardly facing surface  76  on the rim/bill  14 , after which the ends  38 ,  40  can be bent around the side edges  24 ,  26  and under the rim/bill  14 . 
     As one alternative assembly method, the bowed shape of the second item  16  can be pre-selected, with the ends  38 ,  40  of the body  36  pre-bent into the “U” shape of  FIGS. 4 ,  5  and  9 . The second item  16  can then be slid over the rim/bill  14  from front to rear, with the rim/bill  14  being maintained in a shape substantially corresponding to the pre-shaped second item  16 . 
     As a further alternative, the bottom surface  74  of the second item  16  can be laid against the surface  76  without any significant pre-forming of the second item  16 . The second item  16  can then be bent along its length and the ends  38 ,  40  return bent to secure the second item  16  on the rim/bill  14 . 
     In  FIG. 4 , one exemplary bowed shape for the second item  16  and rim/bill  14  is shown. In  FIG. 5 , the second item  16  is reshaped so that the bowing is more significant such that the rim/bill  14  has a narrower shape and a more pronounced curvature.  FIGS. 4 and 5  represent just two different bowed shapes that might be selected. The second item  16  may be shaped in other manners. Aside from changing the bowing shape, the second item  16  may be used to produce other than a continuous curve between the side edges  24 ,  26  of the rim/bill  14 , limited only by the bendability and dimensions of the second item  16 . 
     It is contemplated that the second item  16  can be worn by the user with the second item  16  separated from the headwear item  10 . As one example, the second item  16  can be formed in the shape of a bracelet, as shown in  FIGS. 9 and 10  on an arm  78  of a user. 
     In  FIG. 11 , the second item  16  is shown used as an anklet on a user&#39;s leg  80 . 
     As shown schematically in  FIG. 12 , the second item  16  may be used apart from the headwear item  10  on any limb  82  on a wearer. 
     As a further alternative, as shown in  FIG. 13 , the second item  16  may be used as a band upon the user&#39;s hair  84  or otherwise attached to the hair. 
     As a further alternative, as shown in  FIG. 14 , the second item  16  may be used to attach the same to a clothing item  86  on a user/wearer. 
     In one form, as shown in  FIG. 1 , information, shown generically at  88 , is provided on the front of the crown  12 . Additional information at  90  is provided on the web  48 . The information  88 ,  90  may take any form, such as color, a logo, words, a depiction of a person, place or thing, etc. Generally, the information  88 ,  90  would relate to the same subject matter. As just one example, the information  88  may be a team logo, with the information  90  including the name of the team with which the logo is associated. Virtually any information as is commonly used on headwear is contemplated to be used on the headwear item  10  and the second item  16 . 
     As shown in  FIG. 15 , the invention contemplates that the body  36 ′ may take virtually any form having U-shaped ends  38 ′,  40 ′ to engage the side edges  24 ,  26  of the rim/bill  14 . As just one example, the body  36 ′ may have a single, fixed length, reconfigurable element that may or may not be associated with a web corresponding to the web  48 . 
     As an alternative to the fixed body length, as shown in  FIG. 16 , an adjustable body  36 ″ may be used to alter the effective length between ends  38 ″,  40 ″. 
     As a further alternative, the structures shown in  15  and  16 , rather than having a maintainable body shape, may be made from a chain with a fixed length or a variable length, with the ends thereof attachable at the side edges  24 ,  26  of a rim/bill  14 . 
     As a still further variation, one or more wire elements can be used with a cloth layer that does not extend the full length of the wire(s). 
     The invention is not limited to the particular headwear item shown in  FIG. 2 . As noted previously, virtually any headwear item is contemplated wherein there is a “crown” that maintains the headwear item on a wearer&#39;s head and a rim/bill projecting therefrom. For example, as shown in  FIG. 17 , a headwear item is shown at  10 ′ in the form of a visor. The visor  10 ′ has a crown  12 ′ that extends partially around a wearer&#39;s head and has an open top. A rim/bill  14 ′, constructed generally as the rim/bill  14 , projects angularly away from the crown  12 ′. The second item  16  is attachable to the rim/bill  14 ′ in the same manner as it is attachable to the rim/bill  14 . 
     As noted previously, the invention contemplates virtually a limitless number of different constructions for the second item  16  that can be used with likewise virtually an unlimited number of different types of headwear items. 
     As shown in  FIG. 18 , the invention contemplates the provision of a headwear item with a rim/bill, as shown at block  100 . As shown at block  102 , a second item is provided and attached to the rim/bill, as shown at block  104 . As shown at block  106 , the second item is separated from the rim/bill and worn apart from the rim/bill, as shown at block  108 . Thus, the invention is not limited in terms of the precise construction for the second item  16 , the construction of the headwear item, or the manner of wearing the second item apart from the headwear item. 
     The foregoing disclosure of specific embodiments is intended to be illustrative of the broad concepts comprehended by the invention.