Patent Abstract:
An audio source system may be built into a garment such as a hooded garment in such a way that safety concerns such as with a hooded garment for children are taken into account so that the audio system wiring cannot be made loose causing a danger of strangulation nor can the hood be cinched. This is done by putting speakers into the hood between a lining and an outer layer and passing the wires into the space between them and then into a tube that is open to the hood inner space and down the tube to a pocket in the body of the garment. Also securing tabs are used to prevent cinching action upon pulling the wire.

Full Description:
This application is a continuation of U.S. application Ser. No. 12/978,516 filed on Dec. 24, 2010 now U.S. Pat. No. 8,553,919, which is a continuation-in-part of U.S. application Ser. No. 12/896,880 filed on Oct. 2, 2010 which is a continuation-in-part of U.S. application Ser. No. 12/492,035 filed on Jun. 25, 2009 now U.S. Pat. No. 8,107,653 the content of which is incorporated herein by reference and the priority of which is claimed. 
    
    
     FIELD OF THE INVENTION 
     The invention is in the fields of clothing and wiring for listening to portable audio sources such as MP3 players, CD players, cell phones, Bluetooth devices and the like. In particular for combinations of clothing and such wiring. 
     BACKGROUND 
     Wiring assemblies for portable audio sources for listening are ubiquitous. They are generically called headphones. One type of headphones adapted for portable use are called earbuds or earphones. They have at one end a connector to plug into a source device. This then leads to a pair of wires connected to the devices to be placed at the user&#39;s ears, usually held in or on the ear. 
     A user carries the wiring assembly with her and connects it up to the source device and sets the headphones at the ears. The wiring has to be carried and kept available for use, and it is commonly a nuisance to find it and then to use it. In use it is kept usually outside the clothing, the headphones being at the ears and the audio device held in the hand or placed in a pocket. 
     The wiring may not be waterproof, but recently waterproof wiring has been developed and is available. 
     Certain special problems are presented with hooded garments designed for children due to the danger of choking presented by lanyards for cinching and cinching in general. To provide such a garment with an audio system presents special problems. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a view of an exemplary type of earphones and wiring which is applicable to the present invention. 
         FIG. 2  shows a front view of a hooded garment with earphone wiring built into it according to an embodiment of the invention. 
         FIG. 3  shows a partial view of a garment showing the connector and access wiring extending into a garment pocket. 
         FIG. 4  shows a partial view of a garment with the wiring in a tube sewn into the inside of a garment and entering the channel of the hood. 
         FIG. 5  shows a partial view of a garment with a hood showing a cut-away view of the interior of the inside the channel of the hood with the wiring. 
         FIG. 6  shows the wiring and hollow lanyards as held together in the channel by a barrel. 
         FIG. 7  is a view showing the wiring and hollow lanyards with a tab attached to the barrel for fixing to the garment. 
         FIG. 8  is a section view at  8 - 8  of  FIG. 7  showing the wiring and hollow lanyards fixed to the casing by means of the tab. 
         FIG. 9   a  is a view of the hollow lanyard with the electrical wire and a connection fitting for connection to an earbud. 
         FIG. 9   b  is a view showing the assembled fitting to the earbud. 
         FIG. 10  is a view of the channel portion of a hooded garment showing the wiring inside it and an alternative way of fixing the wiring and lanyards against lateral movement. 
         FIG. 11  is a schematic view of an embodiment of the invention ready for assembly. 
         FIG. 12  is a schematic view of the embodiment of  FIG. 11  showing partial assembly. 
         FIG. 13  is an assembled view of the embodiment of  FIGS. 11 and 12 . 
         FIG. 14  is an enlarged detailed view of an embodiment of the invention of  FIGS. 11 ,  12  and  13 . 
         FIG. 15  is another embodiment of the invention. 
         FIG. 16  is an embodiment of the invention that is specially configured for garments for children. 
         FIG. 17  is a partial exploded view of the configuration of  FIG. 16 . 
         FIG. 18  is a partial view of the configuration of  FIG. 16 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     In the present invention wiring for an audio device, including headphones and earphones are permanently installed into a garment. 
     An exemplary earphone wiring assembly  10  as in  FIG. 1  is of the type including a connector  12  for connecting to an audio source device, typically with paired analog audio transmission wires  14   a  and  14   b  joined together along a joined wire portion  16  for some distance to a separation point  18  typically having a strain relief member  20  from which the transmission wires  14   a ′ and  14   b ′ extend separately terminating at the earphones  22   a  and  22   b . While the term earphone wiring will be used in this description it is intended to mean any of the type with a connection to a source device and a pair of listening instruments, one for each ear. Typically an analog signal travels from the source device to the earphones. 
     In exemplary form the garment is a hooded garment  30  as shown in  FIG. 2 . In other exemplary forms the garment is a conventionally collared shirt, and in still others it has a plain hemmed neck such as a crew neck. In the case of the hooded garment, it may be in jacket form, that is open down the front (with a zipper or other closure means) or in pull-over form like a sweater. However in each case for purposes of embodiments of this invention there is a channel or casing as will be described. In this description the terms left and right refer to the wearer&#39;s left and right. As shown in  FIG. 2 , the earphone wiring  10  is installed into the garment so that the connector  12  is accessible near a pocket  32  and the right and left earphone wires  14   a ′ and  14   b ′ exit the garment inside hollow lanyards (also called drawstrings)  36   a  and  36   b  on each side of the hood  34  near the user&#39;s ears terminating at the right and left earphones  22   a  and  22   b . As will be described in more detail below, the portions of the earphone wiring  10  from the connector  12  to which access is not needed and which runs up to the hood  34  is captured in the garment. Also shown in  FIG. 2  are right and left tubular lanyards  36   a  and  36   b . These are used to cover the earphone wires  14   a ′ and  14   b ′ and also as the hood lanyards, for adjusting (called cinching) the hood  34 . The hollow lanyards are knitted or may be hollow flexible plastic 
       FIG. 3  shows an example of how the wire portion  16  extends into the pocket  32  and exits the inner wall of the pocket  32  through an opening  40  so that it is in the inside of the garment  30 , as further described below with reference to  FIG. 4   
       FIG. 4  shows an example of how the earphone wiring  16  is brought from a location inside the pocket  32  into the hood channel  38 . This is done by passing the joined wire portion  16  through an opening  40  inside the pocket, which opening can be a button hole or a grommet to the inside of the garment. Then it enters a first, lower end of and travels through a channel or casing  42  which is sewn into the inside of the garment, in this case along the stitch line  46  that also attaches a zipper  44 . Then it exits the channel  42  at a second, upper end, and enters the hood channel  38  (also called a casing) which is defined by the stitching  48 , through an opening  50  defined by a button hole or other hole device such as a grommet, entering on the side of the hood channel  38  which is on the interior of the hood  34  and extends to the separation point  18  at which the wires separate. Further detail inside the hood channel  38  is described below. 
     Installation of the wiring can be done with a garment that does not have a pocket, in which case the wiring can simple extend beyond the bottom of the garment, or it can pass through an opening in the garment. 
       FIG. 5  shows a view of the inside of the hood channel  38  with a portion cut-away to show the interior of the channel. The joined portion  16  comprising the wires  14   a  and  14   b  enters the hood channel  38  as described above with reference to  FIG. 4 , and this portion is placed so that the strain relief member  20  at which they separate is approximately at the center of the hood  34 . The right and left separate wires  14   a ′ and  14   b ′ are installed inside the right and left hollow lanyards  36   a  and  36   b  respectively. The assembly at the point where the wires  14   a ′ and  14   b ′ exit the strain relief  20  into the hollow lanyards  36   a  and  36   b  is described in  FIGS. 6-8  below. The right and left hollow lanyards  36   a  and  36   b  with the right and left wires  14   a ′ and  14   b ′ respectively, inside them exit the hood channel  38  through openings  52   a  and  52   b , which in this embodiment are on the outside of the hood channel  38 , although they could be on the inside. 
       FIG. 6  shows an embodiment for a secure “Y” connection of the wires inside the hood channel  38 . In this embodiment the strain relief also called a securing piece  20  is a plastic barrel that has been molded over the separation point  18  where the joined wires  14   a  and  14   b  separate into the separate wires  14   a ′ and  14   b ′. It is also at this point that the wires  14   a ′ and  14   b ′ enter the hollow lanyards  36   a  and  36   b  respectively. The securing device  20  tightly holds the ends of the lanyards with respect to each other and the wires. This will be referred to as the securing point  54 . 
     It is preferable that the lanyards  36   a  and  36   b  with the wires inside them be attached to the garment inside the hood channel  38  to avoid pulling them laterally in one direction or the other such as by uneven pulling. There are various ways that this can done. One way is to secure the assembly to the garment at or near the securing point  54 . In one embodiment this is done as shown in  FIGS. 5 ,  7  and  8  with a fabric strip  56  secured around the securing piece  20 , stitching and gluing being exemplary. It is then co-sewn into the hem stitch  46  which defines the casing or channel  38 . The detail is shown in  FIG. 8  in which the fabric strip  56  is sewn at  58  to help secure it around the securing piece  20 . Then, after it has been set in place, it is co-sewn with the hood channel hem as shown at  60 . 
       FIG. 10  shows another embodiment for fixing the lanyard/wire members against lateral movement. In this embodiment, the securing piece  20  is captured between stitch lines  66  on either side. Of course the stitch lines  66  have to avoid the wiring. 
     As explained above, an embodiment of the invention combines the hood lanyards  36   a  and  36   b  with the separate wire portions  14   a ′ and  14   b ′ so that the hollow lanyards serve two purposes, one is to tighten the hood, and secondly as conduits for the separate wire portions  14   a ′ and  14   b ′. The ends of the lanyards  36   a  and  36   b  are secured to the earphones  22   a  and  22   b , which in the figures are shown as the earbuds type of earphones. 
     To manufacture the assembly so that the wiring is permanently installed in the garment, the separate wires  14   a ′ and  14   b ′ are first strung through the lanyards  36   a  and  36   b . Then the molded barrel  20  is molded into place at the “Y” junction securing point  54  joining the wires and the lanyards at one end. Then the other ends of the combined lanyards and wires are crimped to a strain relief connection fitting  62  as shown in  FIG. 9   a , and then the stripped wire portion  64  is attached to the earbuds  22   a  and  22   b  and the connection fitting  62  is secured to the earbuds  22   a  and  22   b  as shown in  FIG. 9   b.    
     While in this description, the terms right and left have been used to understand the location of the lanyards, the wires and the earphones with respect to the garment; it should be understood that the location may but does not necessarily consistently apply to the attachment to a user&#39;s left and right ear. A user may attach the left earphone to the left ear and the right earphone to the right ear. But a user can elect to do the opposite; and when the lanyards are tied in a conventional bow, the left and right earphones will reverse their relative location. 
     A further embodiment is shown in  FIGS. 11 ,  12  and  13  which are progressive assembly and the enlarged views of  FIG. 14 . In  FIG. 11  there are shown an earbud  102  ready for assembly to a lanyard assembly  104 . The earbud is made up of a housing  106  a sleeve  108 , (also seen as  62  in the description above) and a speaker or electronics assembly  110  and also a crimp element  112 . The lanyard assembly  104  includes a lanyard  114  (described above as  36   a  and  36   b ), typically of woven construction and internal wiring  116  (described above as wires  14   a  and  14   b  on one side and  14   a ′ and  14   b ′ on the other side). Projecting beyond a terminal end  118  of the lanyard, the internal wiring  116 , which consists of a two wire cable, has been stripped to provide bare wire  120  with terminal ends for connection to the speaker assembly  110 . A glue drop is schematically illustrated at  122 . 
     The housing  106  has a generally open interior and an opening  124  at its rear end to snugly, or interferingly receive the sleeve  108  and an opening  128  to receive the speaker assembly  110 . The sleeve  108  has a passageway  130  through it from a front end  132  to a rear end  134 . The passageway  130  may be tapered as shown from front to rear. Although it is shown as straight, the sleeve may have another shape with the passageway extending through it accordingly 
     In  FIG. 12  those same elements are shown partially assembled. To perform the assembly, the lanyard assembly  104  has been threaded through the sleeve  108  to extend beyond the front end  132 . Then, the crimp element  112  in the form of coiled wire has been applied proximate the terminal end  118  of the lanyard assembly  104 , and crimped. This can be seen in  FIG. 14 . The crimp element  112  secures the lanyard  104  and the wire  116  together so that they are fixed together at that point, that is there can be no relative movement between them and no movement of or force on the lanyard  114  is transmitted to the portions of the wires  120  that will be attached in the earbud speaker assembly  110 . The crimping is also shown in enlarged form in  FIG. 14  showing application of the crimp element  112  in the form of a coil of wire before and after crimping. More than one crimp element can be applied to ensure a secure crimp. Other elements can be used as the crimping element which can be closed or crushed down and will secure the lanyard  114  and the wire  120  against relative movement, for example a small lock-washer can be crimped in place. Then, the lanyard assembly  104  is pulled back (see the arrow A in  FIG. 14 ) to pull the crimp element  112  into the passageway  130  where it is firmly captured by the wall of the passageway  130  with the bare wires  120  available for connection, as shown in  FIG. 12 . This is also shown in  FIG. 9   a . The wires  120  are attached to terminals of the speaker assembly  110  and glue  122  is applied into the passageway  130   
     The sleeve  108  is assembled to the housing  106  and the speaker  110  is assembled to the housing  106  where the parts are all fixed together by sonic welding. This final assembly is shown in  FIG. 13  and also in  FIG. 9   b.    
     The wire  120  inside the lanyard  114  is slack as shown by the undulating portion whereby the combination of the slack and the crimping at the end allows any stretching of the lanyard  114  to be applied to the slack of the wire thereby freeing the wire from forces such a pulling on it put on the lanyard  114  and also prevents strain from communicating past the crimp point to the wires inside the housing. That means that as the user pulls on the lanyard such as to tie it or pull the hood tight, due to the slack, the wire  116  will not be subject any stretching or other forces caused by use of the lanyard. In other words, the wire  116  inside the lanyard  114  is independent of the lanyard  114  by reason of the slack and at the same time, the wires  120  beyond the crimp are also free of strain that might be caused by use of the lanyard. 
     Another embodiment is shown in  FIG. 15  in which the lanyard assembly is further developed for a Bluetooth receiver/transmitter  150 . In this embodiment, the connector  12  is connectable to a Bluetooth receiver/transmitter  150 . One of the wires  14   a ′ or  14   b ′ has a microphone  152  connected to it which has an internal pressure switch. The Bluetooth receiver/transmitter  150  is equipped with an on-off switch  154  and other electronic elements common to such devices. The user simply connects the Bluetooth device  150  and can listen to any incoming recorded message or to a live person and can respond by turning on and using the microphone  152 . When the lanyard assembly is used for just listening such as to music via an MP3 player or the like the same wiring performs as described above. 
     Another embodiment of the invention is described with reference to  FIGS. 16 ,  17  and  18 . 
     This embodiment is based on special requirements for children. For children it is not desirable and may be prohibited to allow any means for cinching the hood due to the danger of choking from any dangling cord such as a lanyard or in the case of the present combination from any exposed wiring. The following describes an embodiment of the invention in which there is no lanyard or other cinching means, but does have the built-in wiring and speakers; all the wiring being contained against access or exposure that would create a danger. Also, securing tabs are used at specific points so that the hood cannot be cinched even if the wire is pulled from its accessible end and also to secure the speakers in a selected place in the hood on its right and left sides respectively. The wire from each speaker extends into a hood channel along the hood opening and then into a tube secured to the garment body. The wires can enter the hood channel at any desired selected place. However it is desirable that they enter together and preferably at the center of the hood where the hood seam and the channel stitch line intersect so that it is convenient to leave a space at which the wires enter the hood channel together. The tube is openly secured at the line of joinder of the hood and the body so that the wires pass from the hood channel into the tube with no external exposure or access. A securing tab is installed in the hood at a point proximate to where the wires leave the hood channel and go into the tube. The securing tab is fixed around the wires such as by gluing and is fixed in place by being commonly sewn in the stitch that defines the hood channel. There is a pair of second securing tabs, each one installed proximate one of the speakers. Each of the second securing tabs is fixed around the wire proximate the speaker and is fixed in place by common sewing with the patch that defines the pocket. This helps to hold the wire and the speaker in a relatively fixed position. Also, a protective pad is installed behind each speaker to protect the speakers from shock or other damage such as from a washer or dryer, or simply from being inadvertently struck from outside the hood. The protective pad can be a non-woven fabric such as felt, with sufficient thickness to provide some level of protection, such as 1/32 to ¼ inch thick. It is held in place by being commonly sewn with the patch. 
       FIG. 16  shows an open view of the subject garment.  FIG. 17  is an exploded view of the speaker pocket construction.  FIG. 18  shows detail of the speaker pocket construction and the securing tab installation. Referring to  FIGS. 16 ,  17  and  18  the garment  200  has a hood portion  202  and body portion  204  which are sewn to together along a line of joinder  206 . The hood portion  202  is made with an outside panel  208  and a liner panel  210 . The outside panel  208  has an outer surface  212  which is the exterior of the hood portion  202  and an inner surface  214 . The liner panel  210  has an outer surface  216  which faces the outside panel  208  to define a space  220  between the two panels. A stitch line  222  creates a hood channel  224  within the space  220 . In the space  220 , at a point selected to fit at or near a user&#39;s ears are speakers  226 . 
     Each speaker  226  is secured in a speaker pocket  228  which is made by stitching onto the liner panel  210  a patch  230 . Also, a protective sheet  232  is desirably installed in the speaker pocket  228  on the side of each speaker  226  facing outwardly. For example the protective sheet  232  can be a nonwoven such as felt and can have thickness in the range of about 1/32 to about ¼ inch. The protection will be provided from the hood portion  202  being struck from the outside or from a washing machine or dryer. 
     Wires  234 A and  234 B extend from the each of the speakers  226  respectively in the space  220  and into the hood channel  224 . While the wires  234 A and  234 B can enter the hood channel  224  separately and at any selected place it is desirable that they enter together and also that they enter at a place where a space in the stitching  222  of the hood channel  224  can be allowed an opening so that they may pass through. This is advantageously done at the center of the hood where a central seam  236  of the liner panel  210  occurs. The wires  234 A and  234 B then extend as a pair in the hood channel  224  to the line of joinder  206  where they pass into the tube  236 . The tube  236  is installed at its top end  238  at the seam of the line of joinder  206  but the stitching is done so that the tube  236  is open into the hood channel  224 . In that way the paired wires  234 A and  234 B can pass into the tube  236  with no outside exposure or access. The tube  236  is attached along its length down the body portion  204  by common stitching with installation of a zipper  240  and terminates at a bottom end  242  as near as practical to an opening  244  into pocket  246  (see pocket  32  in  FIG. 3 ). The opening  244  is desirably a button hole or a grommet. As described above in other embodiments, the paired wires  234 A and  234 B are terminated to a connector (see connector  12  in  FIG. 3 ) which is accessible into the pocket  246 , from outside the garment. 
     As seen in  FIG. 16 , in the hood channel  224 , close to the line of joinder  206  a securing tab  248  is fixed to the paired wires  234 A and  234 B It can be fixed by gluing or other means. The securing tab  248  is commonly stitched with the stitching  222  that forms the hood channel  224 . The securing tab  248  will prevent any strain from pulling on the paired wires  234 A,  234 B thereby preventing any cinching of the hood portion  202 . 
     As seen in the magnified view of  FIG. 18 , there is a securing tab  250  fixed on each of wire  234 A and  234 B as it is attached to the respective speaker  226  and is commonly stitched with the patch  230  along stitching  222 . The securing tab  250  then prevents any strain on the respective wire from being transmitted to its point of attachment to the speaker, and also helps steady the speaker in position in the speaker pocket  228 . 
     The foregoing Detailed Description of exemplary and preferred embodiments is presented for purposes of illustration and disclosure in accordance with the requirements of the law. It is not intended to be exhaustive nor to limit the invention to the precise form or forms described, but only to enable others skilled in the art to understand how the invention may be suited for a particular use or implementation. The possibility of modifications and variations will be apparent to practitioners skilled in the art. No limitation is intended by the description of exemplary embodiments which may have included tolerances, feature dimensions, specific operating conditions, engineering specifications, or the like, and which may vary between implementations or with changes to the state of the art, and no limitation should be implied therefrom. This disclosure has been made with respect to the current state of the art, but also contemplates advancements and that adaptations in the future may take into consideration of those advancements, namely in accordance with the then current state of the art. It is intended that the scope of the invention be defined by the Claims as written and equivalents as applicable. Reference to a claim element in the singular is not intended to mean “one and only one” unless explicitly so stated. Moreover, no element, component, nor method or process step in this disclosure is intended to be dedicated to the public regardless of whether the element, component, or step is explicitly recited in the Claims. No claim element herein is to be construed under the provisions of 35 U.S.C. Sec. 112, sixth paragraph, unless the element is expressly recited using the phrase “means for . . . ” and no method or process step herein is to be construed under those provisions unless the step, or steps, are expressly recited using the phrase “comprising step(s) for . . . ”

Technology Classification (CPC): 7