Patent ID: 12253250

DETAILED DESCRIPTION

While the specification concludes with claims defining the features of the invention that are regarded as novel, it is believed that the invention will be better understood from a consideration of the following description in conjunction with the drawing figures, in which like reference numerals are carried forward. It is to be understood that the disclosed embodiments are merely exemplary of the invention, which can be embodied in various forms.

FIG.1Ais a front view of a lighted accessory100for use on apparel, in accordance with some embodiments. The lighted accessory is a device that has, on its front, a raised graphic104, such as, for example, lettering. The raised graphic104is raised relative to the main body102of the accessory100, which also houses the circuitry, battery, light emitting elements, and light spreading/diffusing members. As shown here, the accessory100has a main body102on which is a graphic104in the form of raised stylized lettering that spells “Miami.” The accessory can include controls that allow a user to control the light effect, such as, for example, choosing between brightness levels, colors, flashing patterns, and so on. The main body102of the accessory100is made of a cured silicone material in which the internal components (circuit components, light emitting elements, etc.) are embedded. The controls are provided external to the main body102so as to be accessible, either on a side of the main body102or in a remote portion via wires. The accessory is intended to be affixed or attached to an apparel item, such as a cap.

FIG.1Bis a side elevational view of a lighted accessory, in accordance with some embodiments. A portion of the accessory100at a side/edge of the accessory100is shown here. There is a portion of the main body102, which includes a side having a height108, and on which there is a raised graphic portion104, which has a height108above the main body102. Both the main body102and raised graphic104are made of a transparent or translucent material, such as, for example, silicone, in which there are embedded circuitry components and light emitting elements, as well as light-affecting structure such as light diffusers and colored translucent members for creating color. The shoulders of the main body portion, at the front, and the raised portion, wherein the front surface transitions to a side surface, can be rounded (as opposed to right angles) to enhance the lighting effect.

FIG.1Cis a front view of a baseball style cap110having a lighted accessory device100attached on the front112of the cap, in accordance with some embodiments. The lighted accessory device100is configured in the shape of writing, and contains circuitry, a rechargeable battery, and lighting elements powered by the battery and controlled by the circuitry. The lighted accessory device100can be attached to the front112of the cap110such as by a layer of hook and loop type fastener material, having a layer on the back of the lighted accessory device100and a layer on the front112of the cap100, in some embodiments. Alternatively, the lighting accessory device100can be more permanently attached to the cap110, such as by sewing a periphery of the lighted accessory device100to the front112of the cap110. The lighted accessory device100comprises a body102that is made of molded material that can be transparent or translucent, and in which there can be opaque graphical elements placed. For example, as shown here, an opaque element in the shape of a stylized word (“Miami”) is shown here. Generally, the opaque element or elements are placed in a mold, and then the battery, circuity, and lighting elements are placed in the mold on top of the opaque element(s), and then a moldable material is poured over these components. The mold and the circuit elements are configured so that user controls extend outside of the moldable material and will be accessible by a user once the moldable material cures. In some embodiments the control and charging connector can be outside of the main body and connected by suitable wiring. The moldable material can be, for example, silicone, rubber, plastic, resin, and the like, and is an electrical insulator. Once the material is cured, a layer of fastener material can be adhered on the back side of the device in some embodiments.

Thus, the lighting accessory device includes a body comprised of a cured moldable material. There is at least one graphical element disposed in the cured moldable material of the body at a front of the body. There is also a circuit board disposed behind the graphical element in the cured moldable material of the body. There can be at least one switch disposed on the circuit board, and a power connector disposed on the circuit board. A control portion of the at least one switch extends from inside of the cured moldable material of the body to an outside of the body, and wherein a connector portion of the power connector extends from inside of the cured moldable material of the body to outside of the body. There is aa battery disposed in the cured moldable material of the body. There is also at least one lighting element disposed in the cured moldable material of the body that is controlled by circuitry on the circuit board, responsive to operation of the at least one switch. The cured moldable material of the body fills a complete volume of the body around the at least one graphical element, circuit board, battery, at least one switch, power connector, and at least one lighting element.

FIG.2is a block schematic diagram200of the electrical and electronic elements of a lighted accessory device100, in accordance with some embodiments. A circuit board includes lighting control circuitry202for controlling lighting elements210,212, that can each have multiple light emitting diodes214or similar light producing elements. The circuitry202can also control charging and current/voltage regulation of a battery204. The lighting control circuitry202can be disposed on a circuit board, as are user controls that can include a button switch206, and slide switch208, and a power connector216. In some embodiments the button switch206or the slide switch208may not be used. In some embodiments the slide switch208turns the lighting control circuitry202on/off, and the button switch206causes the lighting control circuit202to control the output of the lighting elements210,212to cycle through different lighting patterns (e.g. constantly on, flashing, phasing between dim and bright). The connector216can be, for example, a micro-USB connector. The switches206,208, and connector216can be supported on the same circuit board as the lighting control circuitry202, and can be positioned near an edge of the mold so that the switch206,208and connector216extend slightly outside of the mold, and are thus not covered by the moldable material when the moldable material is poured into the mold. In some embodiments, the slide switch208, button switch206, and power connector216can be housed together in a remote housing structure, outside the main body102of the lighted accessory device100, and coupled to the lighting control circuitry202via suitable wiring.

FIG.3is a more detail block diagram of circuit functions of a lighted accessory device100, in accordance with some embodiments. There can be a power regulator circuit302that regulates power to the lighting elements (e.g.210,212). The lighting elements210,212can comprises a plurality of light emitting diodes (LEDs). The power regulator302can be controlled by an LED controller304, which can be responsive to the button switch206to cycle between lighting modes or patterns. The USB interface306allows power to be provided to recharge the battery, and can be connected to a USB connector at the side of the lighted accessory device100, or on a remotely located structure coupled to the lighted accessory device via wiring.

FIG.4is an exploded assembly view of a lighted accessory device400, in accordance with some embodiments. The lighted accessory device400can be substantially similar or the same as lighted accessory device100discussed previously. The view shows the elements, other than the body material, that are included in the device, and the mold402in which the elements are placed. The mold402has the desired external shape of the device, and is configured to hold the moldable material and other elements until the moldable material cures and includes a main body portion403and a raised graphic portion405. The electrical and other elements shown here are not shown to scale relative to the mold402as in the actual device being made all of the components represented here fit into the mold402.

In general, the elements are loaded into and arranged in the mold402, and then the moldable material is poured into the mold to fill the volume of the mold402. Generally, one or more graphical elements404are first placed into the mold402, and in particular into the raised section405. The graphical elements404can configured in the shape of some recognizable figure, such as writing or other recognizable images or objects, and they are generally flat, translucent members through which light is emitted. The bottom here is the portion405in which the raised graphic portion (e.g.,104) is formed, and it forms the face of the device400, so the graphical elements404will be at the front of the device400upon completion of the molding process. The graphical elements404can have retaining features406that couple to, and hold a circuit board408in place on the back of the graphical element404.

The circuit board408has the majority of the circuitry disposed on the circuit board, including, for example one or more switches410, and a power connector (not shown here) that are arranged on the circuit board to extend outside of the mold402. A battery412can be disposed on the circuit board408or elsewhere behind the graphical element404but is otherwise wired to the circuit board408. One or more lighting elements414are connected to the circuit board408via wiring416and controlled by circuitry on the circuit board408. The lighting elements414can also be retained on the back of the graphical element404such as by additional retaining features such as406used to hold the circuit board408in place. In some embodiments a light diffusing element407can be placed between the lighting elements414and the graphical elements404to prevent the appearance of “hot spots” and diffuse the light emitted by the light emitting elements414across the graphical elements404. The retaining features406can be clips or simply posts to align the battery, lighting elements, and circuit board.

The elements shown here and loaded in a vertical stack into the mold402, and then a curable transparent or translucent material is poured over the elements into the mold and allowed to cure. The material can be, for example, silicone, plastic, rubber, or other pourable materials that will harden. The circuit board408can be a flexible two-sided circuit board on which the lighting control circuitry and lighting elements414, as well as the battery412, and connectors/switches410can be mounted. As mentioned, it is intended that all of the elements shown here can be placed entirely in the mold402such that the back side of the resulting lighted accessory device, which will be the top/uppermost surface of the cured mold material, is substantially flat. In some embodiments a section of material418can then be affixed to the lighted accessory device, which can include a layer of reflective material419to reflect light towards the front of the lighted accessory device. The backside421of the material418can be opaque and non-reflective, and can have a hook or loop material disposed thereon to join to a corresponding hook/loop material on an apparel article. Alternatively, the mold can include a section420around the top of the mold402that creates a periphery that extends outward from the base of the main body of the lighted accessory device, and which allows the lighted accessory device to be sewn to an apparel article. The material418can extend into the periphery420to strengthen to periphery region.

FIG.5is a downward view of the rear of a lighted accessory device400in a mold402, in accordance with some embodiments. his view shows the elements in the mold402prior to pouring the moldable material. There is seen a graphical element404that is a stylized graphic depicting the word “Miami” as is seen inFIG.1. On top of the graphical element404is the light diffuser elements407, and on top of the light diffuser407is a circuit board408that includes a battery412. A push button switch410is disposed on the circuit board408, and extends, horizontally, outside of the mold402to ensure that a user can access and operate the push button switch410. Likewise, a slide switch512is mounted on the circuit board408in a position that it also extends outside of the mold402. And a power or micro-USB connector514is also disposed on the circuit board408and extends outside of the mold402. The circuit board408includes circuitry for operating the lighting elements414, that are wired to the circuit board408, and which can include one or more light producing devices (e.g. LEDs). Retaining features406can extend from the back of the graphical element404and are positioned and configured to hold the circuit board506in place during the molding process. Similar features can be used for the lighting elements414. Once the various components are arranged in the mold402as shown, a curable material is then poured into the mold402, filling in spaces, and covering most, if not all of the components, leaving only the portions of the switches410,512, and power connector514that are outside of the mold exposed.

It will be appreciated that the graphic element404will fit only into the raised portion405of the mold, and the raised portion405will be shaped in correspondence with the graphic. Thus, if the graphic is writing, such as a stylized depiction of “Miami,” then the raised portion will only be raised where the portions of the stylized writing are located. The graphic elements404are simply translucent flat sections of material than, when looked at from the front, form the desired graphic. Thus, the material of the graphic element404can be, for example, frosted mylar sheeting, colored tissue paper, or any other suitably translucent, flat material that be cut/configured to the desired graphic. The light diffuser407can cover substantially the entire mold, and can be a sheet of transparent material that is frosted on the outward-facing side (e.g. the side adjacent the graphic member404). The retaining member406can pass through slots cut into the light diffuser407, if necessary. Also, it will be appreciated that the cover element418is not shown here as it would cover and obscure the view of the other elements in the mold402.

Thus, the method of making the lighted accessory device includes providing a mold having a shape of an outline of a graphic element, the mold having a main body portion, and a raised portion extending downward at a bottom of the mold, the raised portion having a configuration that corresponds to the graphic element. The method further includes placing the graphic element into the raised portion of the mold, the graphic element being translucent. The method further includes placing at least one lighting element over the graphic element, and placing a lighting control circuit into the mold that is operable coupled to the at least one lighting element. The method also includes placing a battery in the mold that is operably coupled to the lighting control circuit and the at least one lighting element. The method also includes pouring a curable transparent material into the mold, covering the graphic element, at least one lighting element, lighting control circuit, and battery, and curing the curable transparent material.

FIG.6is a rear view of a lighted accessory device100including a layer of fastening material418for attachment to an apparel article, in accordance with some embodiments. In this view the moldable material has been poured over the components shown inFIG.5, and the poured material has been cured. Further, a patch of material418has been adhered on the cured material that allows the device100to be fastened onto apparel having a corresponding fastening material. The patch418can be, for example, a layer of hooks for a hook and loop interface, where the apparel has a patch of loop material to which the device can then be fastened. Alternatively, the patch418can simply be an opaque member prevents light from escaping at the back side of the device100, and can include reflective material on the interior side (e.g.,419). The device100shown here can be the same as that shown inFIG.1attached to the hat, but it is shown from the rear here, before being placed onto the hat.

FIG.7shows a back view of the lighted accessory device100for use with an apparel article, in accordance with some embodiments. In this view, the periphery420is used to sew the device100to an apparel article, and there is no attachment material present on layer418, such as hook/loop material. The inset shows a side view (rotated ninety degrees) to show the raised portion104and the main body102having a sidewall702. The periphery420extends from the sidewall702at the back side of the device100around the perimeter of the device. Although not indicated here for the sake of clarity, the material418can extend to the outward perimeter of the periphery, as shown in the inset704, in order to strengthen the periphery420.FIG.8shows a front view800of a hat802on which a lighted accessory device100has been sewn, in accordance with some embodiments. Stitching806passes through the periphery420and the material of the hat, and holds the device100to the hat.

FIG.9shows a side perspective view of a hat900having a lighted accessory device100, in which the control and power connector are located remotely in the hat from the lighted accessory device, in accordance with some embodiments. A remote connector902is coupled to the device100by wires908, which can be, for example, a USB cable or equivalent. The wires908can pass through the material of the hat900in a location between the hat900and the back side of the device100, and run along in the inside of the hat900. Alternatively, in some embodiments, the remote connector902and wires908can be on the outside of the hat900. In the inset910there is shown an end view902aand a top view902bof the remote connector902. In the end view902athe power connector904can be seen, along with the profile of the mode button906, which can be substantially the same as the button switch206. In the top view902bthe mode switch906is shown at the top surface. A power switch can also be included on the remote connector902, or it can be located on the side of the device100. The power connector904can be a common USB connector that allows charging of the battery. As shown, the remote connector902can be positioned at a side of the hat, but can also be positioned at other locations around the hat.

Thus, according to some embodiments, there is provided a hat that includes an exterior surface and there is a lighting device attached to the exterior surface. The lighting device includes a body comprised of a cured moldable material having a main body portion and a raised portion at a front of the main body portion. There is also at least one graphical element disposed in the cured moldable material of the body in the raised portion. There is also at least one lighting element disposed in the cured moldable material of the body behind the graphical element in the cured moldable material of the body. There is a lighting control circuit disposed in the cured moldable material of the body behind the graphical element which is configured to control an operation of the at least one lighting element. There is also a battery disposed in the cured moldable material of the body, and that is operably coupled to the at least one lighting element and the lighting control circuit. The cured moldable material of the body fills a complete volume of the body around the at least one graphical element, lighting control circuit, battery, and the at least one lighting element.

The inventive embodiments provide for a lighting device and an apparel article using a lighting device that is made of a molded, cured body, where the material of the body is transparent or translucent. The material of the body can be clear or colored. In the body there is a graphic element or elements disposed at a front of the body, preferably in a raised portion that extends forward from a front of the body. There is also a lighting element, control circuit, and battery disposed in the body. As a result, the components in the body are protected from water, and provide an attractive lighting effect.