Abstract:
A system for interchangeable customized headwear is provided that improves the user experience and attractiveness of safety products, especially safety products designed to protect the head. The system provides for interchangeable customized outer coverings that can be replaced and/or reoriented. In one embodiment, a shell has a plurality of shell connectors disposed on a surface of the shell. An outer covering has a pre-determined shape and a plurality of outer covering connectors, each outer covering connector configured to couple to an associated shell connector. In one embodiment, the pre-determined shape is one of: a baseball cap shape, fitted baseball cap shape, military-style cap shape, trucker-style cap shape, cowboy hat shape, jockey hat shape, and winter beanie hat shape. In one embodiment, the plurality of shell connectors is operable to couple the outer covering to the shell in at least two alternate orientations.

Description:
FIELD 
       [0001]    The present invention relates generally to the field of personal safety devices, and more particularly to safety headwear. 
       BACKGROUND 
       [0002]    Modern safety equipment increasingly takes advantage of advanced materials. In each subsequent generation, safety devices made from these materials are generally more durable, lighter-weight, and provide more protection than previous generations. As such, consumers who purchase the latest generation of safety devices frequently expect their purchase to remain in operational service for a long period of time. 
         [0003]    Additionally, the cost to manufacture safety devices has generally fallen with each subsequent generation. However, advances in safety engineering have improved the safety technology embodied in these devices, which often embody proprietary technology. As such, high-end consumer safety devices sometimes command a high price, even where the cost of manufacturing is relatively low. 
         [0004]    Together, the price of high-end safety equipment and the consumer expectation of durability combine to drive expectations of ever-longer service expectations. That is, consumers frequently expect the safety equipment they purchase to last for a long period of time. 
         [0005]    But typical safety equipment, especially helmets and other equipment intended for wear on the head, are designed with fixed non-functional design characteristics. For example, common bicycle helmets have a fixed shape, color, and style, which do not and cannot change over the service life of the helmet. As the price and service life increase, consumers are forced to choose at the time of purchase a helmet style that may be increasingly unsatisfactory as time passes. 
         [0006]    In some cases, consumers have attempted to customize their existing safety headwear, using decals, paint, and/or other adornments. But the known approaches offer limited options. Additionally, changing between appearances is often prohibitively difficult and time consuming. Further, some modifications may become undesirable, and would be costly to reverse. 
       SUMMARY 
       [0007]    In a general aspect of the invention, a system is provided for interchangeable customized headwear. The system includes a shell having a plurality of shell connectors disposed on a surface of the shell. The system also includes an outer covering having a pre-determined shape and a plurality of outer covering connectors, each outer covering connector configured to couple to an associated shell connector. 
         [0008]    In a preferred embodiment, a plurality of shell connectors is disposed on an outer surface of the shell. In another embodiment, a plurality of shell connectors is disposed on an inner surface of the shell. In another embodiment, the plurality of shell connectors includes a shell connector disposed at an apex of the shell. 
         [0009]    In another preferred embodiment, a shell connector and an outer covering connector form a snap-type connection. In another embodiment, a shell connector and an outer covering connector form a hook-and-loop-type connection. In another embodiment, one of the plurality of shell connectors is a rotatable snap-type connector that is disposed at an apex of the shell; and one of the plurality of outer covering connectors is a rotatable snap-type connector that is configured to couple to the one of the plurality of shell connectors. 
         [0010]    In yet another preferred embodiment, the plurality of shell connectors includes a first type and a second type of connector; and the plurality of outer covering connectors includes the first type and the second type of connector. In another embodiment, the plurality of shell connectors includes a first type and a second type of connector; the plurality of outer covering connectors includes the first type and the second type of connector; the first type of connector is a snap-type connector; and the second type of connector is a hook-and-loop-type connector. In another embodiment, the plurality of shell connectors includes a first type and a second type of connector; the plurality of outer covering connectors includes the first type and the second type of connector; the first type of connector is a snap-type connector; the second type of connector is a hook-and-loop-type connector; and the first and second types of connector are disposed in alternating fashion over the shell surface. 
         [0011]    In still another preferred embodiment, the pre-determined shape is one of: a baseball cap shape, fitted baseball cap shape, military-style cap shape, trucker-style cap shape, cowboy hat shape, jockey hat shape, and winter beanie hat shape. 
         [0012]    In yet another preferred embodiment, the shell has a plurality of shell inner surface connectors disposed on an inner surface of the shell; and the outer covering has a fitting flap having a plurality of outer covering inner surface connectors configured to couple to the shell inner surface connectors. In another embodiment, a shell inner surface connector and an outer covering inner surface connector form a hook-and-loop-type connection. In another embodiment, the plurality of shell inner surface connectors includes a first type and a second type of connector; and the plurality of outer covering inner surface connections includes the first type and the second type of connector. In another embodiment, the plurality of shell inner surface connectors includes a first type and a second type of connector; the plurality of outer covering inner surface connections includes the first type and the second type of connector; the first type of connector is a snap-type connector; and the second type of connector is a hook-and-loop-type connector. 
         [0013]    In another embodiment, the plurality of shell inner surface connectors includes a first type and a second type of connector; the plurality of outer covering inner surface connectors includes the first type and the second type of connector; the first type of connector is a snap-type connector; the second type of connector is a hook-and-loop-type connector; and the first and second types of connector are disposed in alternating fashion around the shell outer surface. In another embodiment, the plurality of shell connectors is disposed on an outer surface of the shell such that the plurality of outer covering connectors is operable to couple the outer covering to the shell in at least two alternate orientations. 
         [0014]    In still another preferred embodiment, the plurality of shell connectors is disposed on an outer surface of the shell such that the plurality of outer covering connectors is operable to couple the outer covering to the shell in alternate orientations at regular angular increments. In another embodiment, the plurality of shell connectors is disposed on an outer surface of the shell such that the plurality of outer covering connectors is operable to couple the outer covering to the shell in alternate orientations at a plurality of angular displacements. 
         [0015]    In yet another preferred embodiment, the shell is a sports helmet. In another embodiment, the shell is a motorcycle helmet. 
         [0016]    In still another preferred embodiment, the system includes an alternate outer covering having a pre-determined shape different from the pre-determined shape of the outer covering; and a plurality of outer covering connectors, each outer covering connector configured to couple to an associated shell connector. In another embodiment, the plurality of outer covering connectors of the alternate outer covering is disposed in the same arrangement as the plurality of outer covering connectors of the outer covering. 
         [0017]    In another general aspect of the invention, a system is provided for interchangeable customized headwear. The system includes a shell having a plurality of shell connectors disposed on an outer surface of the shell. The plurality of shell connectors includes a shell connector disposed at an apex of the shell. The system includes an outer covering having a pre-determined shape and a plurality of outer covering connectors, each outer covering connector configured to couple to an associated shell connector. The system includes a first type of shell connector and a first type of outer covering connector together forming a hook-and-loop-type connection. The system also includes a second type of shell connector and a second type of outer covering connector together forming a snap-type connection. The first and second types of connector are disposed in alternating fashion on the shell outer surface. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWING 
         [0018]    The invention will be more fully understood from the following detailed description, in conjunction with the following figures, wherein: 
           [0019]      FIG. 1  is a generalized perspective diagram showing a safety headwear system having interchangeable outer coverings for providing customizable appearances to a shell; 
           [0020]      FIGS. 2A and 2B  are generalized perspective diagrams showing multiple views of an alternate shell of the safety headwear system of  FIG. 1 ; 
           [0021]      FIGS. 3A and 3B  are generalized perspective diagrams showing multiple views of an alternate outer covering of the safety headwear system of  FIG. 1 ; 
           [0022]      FIG. 4  is a generalized perspective diagram showing an outer covering and fitting flap of the safety headwear system of  FIG. 1 ; 
           [0023]      FIG. 5  is a generalized side view diagram showing an outer covering and fitting flap coupled to a shell of the safety headwear system of  FIG. 1 ; 
           [0024]      FIGS. 6A and 6B  are generalized perspective diagrams showing multiple views of an alternate outer covering of the safety headwear system of  FIG. 1 , configured in a “trucker hat” shape; 
           [0025]      FIGS. 7A and 7B  are generalized perspective diagrams showing multiple views of an alternate outer covering of the safety headwear system of  FIG. 1 , configured in a “jockey hat” shape; 
           [0026]      FIGS. 8A and 8B  are generalized perspective diagrams showing multiple views of an alternate outer covering of the safety headwear system of  FIG. 1 , configured in a “baseball hat” shape; 
           [0027]      FIGS. 9A and 9B  are generalized perspective diagrams showing multiple views of an alternate outer covering of the safety headwear system of  FIG. 1 , configured in a “winter beanie hat” shape; and 
           [0028]      FIGS. 10A and 10B  are generalized perspective diagrams showing multiple views of an alternate outer covering of the safety headwear system of  FIG. 1 , configured in a “cowboy hat” shape. 
       
    
    
     DETAILED DESCRIPTION 
       [0029]      FIG. 1  is a block diagram showing an embodiment of the invention for a safety headwear system having interchangeable outer coverings for providing customizable appearances. Specifically,  FIG. 1  shows a headwear system  100  having an outer covering  102  configured to couple to a shell  105 , as described in more detail below. 
         [0030]    In the illustrated embodiment, shell  105  is an otherwise conventional safety device configured to wear on the head. In one embodiment, shell  105  is an otherwise conventional helmet or hardhat, modified as described herein. In an alternate embodiment, shell  105  is a medical device, such as a seizure helmet, modified as described herein. One skilled in the art will understand that shell  105  can be configured as a wide variety of headwear devices, both expressly for safety and otherwise. 
         [0031]    In the illustrated embodiment, outer covering  102  is configured in the style of a typical baseball cap, and includes a bill  140 . As shown, outer covering  102  couples to shell  105 , thereby changing the appearance of shell  105 . Additional features of outer covering  102  are described in more detail below. 
         [0032]    Outer covering  102  includes a plurality of outer covering connectors. In the illustrated embodiment, outer covering  102  includes an apex outer covering connector  110  and a plurality of radial outer covering connectors  115 . As shown, apex outer covering connector  110  is disposed at or near an apex of the hemispherical-type outer covering  102 . As used herein, a hemispherical-type outer covering is an outer covering that defines an imperfect hemisphere. In the illustrated embodiment, apex outer covering connector  110  is disposed on an inner surface of outer covering  102 , in approximately the same location as the top button on a typical baseball cap. 
         [0033]    In the illustrated embodiment, radial outer covering connectors  115  are disposed around an inner surface of outer covering  102 , generally in the vicinity of the edge of outer covering  102 . In one embodiment, radial outer covering connectors  115  are configured as the same type of connector as apex outer covering connector  110 . In an alternate embodiment, one or more radial outer covering connectors  115  are configured as a different type of connector than apex outer covering connector  110 . Generally, as used herein, a connector “type” refers to the particular connector mechanism that couples one connector to another. For example, one connector type is a “snap” type, where one connector is a male snap, configured to fit into a female snap. Another connector type is a “hook and loop” type, where one connector is a patch of fabric hooks configured to catch on a patch of fabric loops. One skilled in the art will appreciate that a wide variety of connector types can be used without departing from the spirit of the invention disclosed herein. 
         [0034]    Generally, apex outer covering connector  110  and radial outer covering connectors  115  are configured to couple to corresponding connectors on shell  105 . For example, shell  105  includes an apex shell connector  120  and a plurality of radial shell connectors  125 . As shown, apex shell connector  120  is disposed at or near an apex of the hemispherical-type shell  105 . As used herein, a hemispherical-type shell is a shell that defines an imperfect hemisphere. For example, a typical motorcycle helmet, a typical bicycle helmet, and a typical sports helmet are all hemispherical-type shells. In the illustrated embodiment, apex shell connector  120  is disposed on an outer surface of shell  105 , in approximately the same location as the top button on a typical baseball cap. 
         [0035]    In the illustrated embodiment, radial shell connectors  125  are disposed around an outer surface of shell  105 , generally in the vicinity of the edge of shell  105 . In one embodiment, radial shell connectors  125  are configured as the same type of connector as apex shell connector  120 . In an alternate embodiment, one or more radial shell connectors  125  are configured as a different type of connector than apex shell connector  120 . 
         [0036]    Generally, in operation, outer covering  102  is configured to couple to shell  105  so as to provide an alternate appearance for shell  105 . For example, in the illustrated embodiment, apex outer covering connector  110  couples to apex shell connector  120 , thereby fastening outer covering  102  to shell  105 . In one embodiment, the apex connectors (apex outer covering connector  110  and apex shell connector  120 ) couple rotably, so that outer covering  102  is free to revolve about shell  105 . 
         [0037]    Similarly, in the illustrated embodiment, one or more of the radial outer covering connectors  115  couple to an associated radial shell connector  125 . As such, the radial connectors (radial outer covering connector  115  and radial shell connector  125 ) fasten outer covering  102  to shell  105  in a particular orientation. In one embodiment, a user can unfasten and refasten the apex connectors and radial connectors, to change the orientation of the outer covering  102  to shell  105 . For example, a user may desire the bill  140  to face a particular direction relative to the user. In embodiments where the apex connectors couple rotably, a user need unfasten only the radial connectors, refastening the radial connectors in to secure outer covering  102  in the desired orientation. 
         [0038]      FIGS. 2A and 2B  are generalized perspective drawings showing an exemplary shell  105  in an alternate embodiment. As shown, shell  105  includes an apex shell connector  120  and a plurality of radial shell connectors  125 . Also as shown, shell  105  includes a plurality of radial shell connectors  130 . Generally, radial shell connectors  125  are disposed on the outside of shell  105 . Generally, radial shell connectors  130  are disposed on the inside of shell  105 , as described in more detail below, in conjunction with  FIGS. 4 and 5 . 
         [0039]    In the illustrated embodiment, radial shell connectors  125  are disposed approximately equidistant from each other. Similarly, in the illustrated embodiment, radial shell connectors  130  are disposed approximately equidistant from each other. One skilled in the art will understand that the exact distribution of radial shell connectors can be modified without departing from the spirit of the invention herein. For example, in one embodiment, the radial shell connectors are disposed so as to be operable to support at least two orientations of an attached outer covering  102 . In another embodiment, the radial shell connectors are disposed so as to be operable to support a plurality of orientations of an attached outer covering  102 , each orientation at a discrete angular displacement to neighboring orientations. In another embodiment, the radial shell connectors are disposed so as to be operable to support a plurality of orientations of an attached outer covering  102 , in a plurality of angular displacements. 
         [0040]      FIGS. 3A and 3B  are generalized perspective drawings showing an exemplary outer covering  102  in one embodiment. As shown, outer covering  102  includes an apex outer covering connector  110  and a plurality of radial outer covering connectors  115 . Generally, radial outer covering connectors  115  are disposed on the inside of outer covering  102 , as described in more detail below, in conjunction with  FIGS. 4 and 5 . 
         [0041]    In the illustrated embodiment, radial outer covering connectors  115  are disposed approximately equidistant from each other. One skilled in the art will understand that the exact distribution of radial outer covering connectors can be modified without departing from the spirit of the invention herein. For example, in one embodiment, the radial outer covering connectors are disposed so as to be operable to support at least two orientations when coupled to a shell  105 . In another embodiment, the radial outer covering connectors are disposed so as to be operable to support a plurality of orientations when coupled to a shell  105 , each orientation at a discrete angular displacement to neighboring orientations. In another embodiment, the radial outer covering connectors are disposed so as to be operable to support a plurality of orientations when coupled to a shell  105 , in a plurality of angular displacements. 
         [0042]      FIG. 4  is a generalized perspective drawing showing an exemplary outer covering  102  in one embodiment. As shown, outer covering  102  includes an apex outer covering connector  110  and a plurality of radial outer covering connectors  115 . Generally, radial outer covering connectors  115  are disposed on the inside of outer covering  102 . 
         [0043]    In the illustrated embodiment, outer covering  102  also includes a fitting flap  405 . As described in more detail below, fitting flap  405  is an extension of shell  102 , configured to couple to radial shell connectors disposed on the inside of shell  105 . Fitting flap  405  can be constructed from the same material used to manufacture outer covering  102 , or from different material. 
         [0044]    In the illustrated embodiment, fitting flap  405  includes a plurality of flap connectors  415 . In the illustrated embodiment, flap connectors  415  are disposed around an inner surface of fitting flap  405 . In one embodiment, flap connectors  415  are configured as the same type of connector as apex outer covering connector  110  and/or one or more radial outer covering connectors  115 . In an alternate embodiment, one or more flap connectors  115  are configured as a different type of connector than apex outer covering connector  110  and radial outer covering connectors  115 . Generally, fitting flap  405  is configured to couple to shell  105  through the plurality of flap connectors  115 , as described below. 
         [0045]    For example,  FIG. 5  is a generalized side view cutaway drawing showing an exemplary outer covering  102  with a fitting flap  405  coupled to a shell  105 . As shown, a radial outer covering connector  115  of outer covering  102  couples to a radial shell connector  120  of shell  105 . In the illustrated embodiment, fitting flap  405  folds over a rim of shell  105 , and a flap connector  415  couples to a radial shell connector  130  disposed on the inner surface of shell  105 . So configured, the fitting flap  405  provides additional connectors to secure outer covering  102  to shell  105 . Additionally, fitting flap  405  can also be configured with a particular thickness, operable to improve the fit of shell  105  when worn by a user. 
         [0046]    Thus, the novel headwear system described herein provides an interchangeable outer covering that can be attached and detached from a shell. As described above, the outer covering can be configured in a wide variety of shapes, including a baseball cap shape, fitted baseball cap shape, military-style cap shape, trucker-style cap shape, cowboy hat shape, jockey hat shape, and winter beanie hat shape. 
         [0047]    For example,  FIGS. 6A and 6B  are generalized perspective drawings showing an exemplary outer covering  102 , configured with a “trucker hat” shape. As shown, outer covering  102  includes an apex outer covering connector  110  and a plurality of radial outer covering connectors  115 . Generally, apex outer covering connector  110  and radial outer covering connectors  115  are disposed on the inside of outer covering  102 , as described above. Additionally, in the illustrated embodiment, outer covering  102  includes a solid fabric section  610  and a mesh fabric section  615 , configured in the style of a “trucker hat.” In the illustrated embodiment, outer covering  102  also includes a simulated adjustment strap  605 , configured to appear as a typical adjustment strap of a conventional cap. 
         [0048]      FIGS. 7A and 7B  are generalized perspective drawings showing an exemplary outer covering  102 , configured with a “jockey hat” shape. As shown, outer covering  102  includes an apex outer covering connector  110  and a plurality of radial outer covering connectors  115 . Generally, apex outer covering connector  110  and radial outer covering connectors  115  are disposed on the inside of outer covering  102 , as described above. Additionally, in the illustrated embodiment, outer covering  102  includes a short bill  710 , a pair of buttons  715 , a simulated chin strap  705 , and a top button  720 , which together are configured in the style of a traditional riding helmet or “jockey hat.” 
         [0049]      FIGS. 8A and 8B  are generalized perspective drawings showing an exemplary outer covering  102 , configured with a “baseball hat” shape. As shown, outer covering  102  includes an apex outer covering connector  110  and a plurality of radial outer covering connectors  115 . Generally, apex outer covering connector  110  and radial outer covering connectors  115  are disposed on the inside of outer covering  102 , as described above. Additionally, in the illustrated embodiment, outer covering  102  also includes a simulated adjustment strap  605 , configured to appear as a typical adjustment strap of a conventional baseball hat. 
         [0050]      FIGS. 9A and 9B  are generalized perspective drawings showing an exemplary outer covering  102 , configured with a watch cap or “winter beanie hat” shape. As shown, outer covering  102  includes an apex outer covering connector  110  and a plurality of radial outer covering connectors  115 . Generally, apex outer covering connector  110  and radial outer covering connectors  115  are disposed on the inside of outer covering  102 , as described above. Additionally, in the illustrated embodiment, outer covering  102  includes a fabric roll  905 , configured in the style of a traditional watch cap or “winter beanie hat.” 
         [0051]      FIGS. 10A and 10B  are generalized perspective drawings showing an exemplary outer covering  102 , configured with a “cowboy hat” shape. As shown, outer covering  102  includes an apex outer covering connector  110  and a plurality of radial outer covering connectors  115 . Generally, apex outer covering connector  110  and radial outer covering connectors  115  are disposed on the inside of outer covering  102 , as described above. Additionally, in the illustrated embodiment, outer covering  102  includes a wide brim  1005 , and ridges  1010 , which together are configured in the style of a traditional western rodeo hat or “cowboy hat.” 
         [0052]    Other modifications and implementations will occur to those skilled in the art without departing from the spirit and scope of the invention as claimed. Accordingly, the above description is not intended to limit the invention except as indicated in the following claims.