VISOR ASSEMBLY FOR A CAP

Abstract

A cap assembly is disclosed herein. The cap assembly includes a crown assembly and a visor assembly. The crown assembly includes a crown and a sweatband. The visor assembly include a visor and a connector. The visor has a concave edge. The connector extends from proximate the concave edge to between the sweatband and the crown.

Description

TECHNICAL FIELD

The present disclosure generally pertains to caps. More particularly this application is directed toward a visor assembly for a cap.

BACKGROUND

Caps are often purchased for their subtle differences in appearance and personal aesthetic appeal. Caps can come in a variety of styles, colors, and patterns. However, with the current available caps, there are limitations on the aesthetic possibilities that stem from manufacturing limitations.

The present disclosure is directed toward improvements in the art.

SUMMARY

A visor assembly for a cap is disclosed herein. The visor assembly includes a visor having a visor top surface, a visor bottom surface, a concave edge extending between the visor top surface and the visor bottom surface. The concave edge has a first end, and a second end opposite the first end. The visor further includes a front edge extending from adjacent the first end to adjacent the second end. The visor assembly further includes a connector. The connector has a connector top portion positioned adjacent to the visor top surface. The connector top portion has a connector top portion edge located proximate to the concave edge. The connector top portion edge extends from proximate the first end to proximate the second end. The connector further includes a connector bottom portion positioned adjacent to the visor bottom surface and spaced from the connector top portion. The connector bottom portion has a connector bottom portion edge positioned proximate to the concave edge. The connector bottom portion edge extends from proximate the first end to proximate the second end. The connector further includes a connector back portion extending from proximate the concave edge and away from the front edge.

BRIEF DESCRIPTION OF THE FIGURES

The details of embodiments of the present disclosure, both as to their structure and operation, may be gleaned in part by study of the accompanying drawings, in which like reference numerals refer to like parts, and in which:

FIG. 1 is a front view of an exemplary cap assembly;

FIG. 2 is a bottom view of the cap assembly from FIG. 1;

FIG. 3 is a cross section view of a portion of the cap assembly from FIG. 1 along line from FIG. 2;

FIG. 4 is a top view of the visor from FIG. 1 isolated away from the cap assembly;

FIG. 5 is a top view of an exemplary embodiment of a visor;

FIG. 6 is a top view of an exemplary embodiment of a visor;

FIG. 7 is a top view of an exemplary embodiment of a visor;

FIG. 8 is a top view of the visor assembly from FIG. 1;

FIG. 9 is a sectional view of the visor assembly shown in FIG. 8 along line IX-IX from FIG. 8;

FIG. 10 is a sectional view of an exemplary visor assembly;

FIG. 11 is a sectional view of an exemplary visor assembly;

FIG. 12 is a sectional view of an exemplary visor assembly;

FIG. 13 is a sectional view of an exemplary visor assembly;

FIG. 14 is a sectional view of an exemplary visor assembly;

FIG. 15 is a sectional view of an exemplary cap assembly;

FIG. 16 is a top view of an exemplary embodiment of a visor;

FIG. 17 is a top view of an exemplary embodiment of a visor;

FIG. 18 is a sectional view of an exemplary visor assembly;

FIG. 19 is a sectional view of an exemplary visor assembly;

FIG. 20 is a sectional view of an exemplary visor assembly; and

FIG. 21 is a sectional view of an exemplary visor assembly.

DETAILED DESCRIPTION

The detailed description set forth below, in connection with the accompanying drawings, is intended as a description of various embodiments and is not intended to represent the only embodiments in which the disclosure may be practiced. The detailed description includes specific details for the purpose of providing a thorough understanding of the embodiments. However, it will be apparent to those skilled in the art that embodiments of the invention can be practiced without these specific details. In some instances, well-known structures and components are shown in simplified form for brevity of description.

FIG. 1 is a front view of an exemplary cap assembly. Some of the features and surfaces have been left out, spaced apart, and/or exaggerated (here and in other figures) for visual clarity and ease of explanation. A cap assembly 100 (sometimes referred to as a cap or hat) includes a crown assembly 400 and a visor assembly 200. The crown assembly 400 may be sized to fit a person's head similar to a typical baseball cap. The visor assembly 200 can include a connector 300 and a visor 210. The visor 210 may be shaped similar to a visor of typical baseball cap and can be disposed proximate the base of the crown assembly 400.

FIG. 2 is a bottom view of the cap assembly from FIG. 1. The crown assembly 400 includes a crown 410 and sweatband 450. The sweatband 450 can be sewn to the crown 410 adjacent to the base of the crown. The visor 210 can extend from adjacent to the connector 300 to away from the crown assembly 400. A portion of the connector 300 can be positioned between the visor 210 and the crown assembly 400. In an embodiment, the connector 300 partially covers the visor 210. In an embodiment the majority of the visor 210 is exposed and not covered by the connector 300.

FIG. 3 is a cross section view of a portion the cap assembly from FIG. 1 along line in FIG. 2. Components of the cap assembly 100 are shown schematically for ease of drafting and visual clarity. Some components are visually represented spaced apart (here and in other figures), but can make contact with one another when assembled together as visor assemblies and cap assemblies. The connector 300 is shown in greater detail on FIG. 9.

The visor 210 includes a visor top surface 220 disposed at the top face of the visor 210, a concave edge 230 disposed proximate to the crown assembly 400 and the connector 300, a front edge 231 disposed opposite from the concave edge 230, and a visor bottom surface 240 disposed on the bottom face of the visor 210. The connector 300 includes a connector top portion 310, a connector bottom portion 320, a connector end portion 350, and a connector back portion 340 (sometimes referred to as first connector back portion).

The connector top portion 310 can be positioned proximate to the visor top surface 220. In an embodiment the connector top portion 310 is oriented substantially parallel with the visor top surface 220. The connector top portion 310 can have a connector top portion edge 311. The connector top portion edge 311 can be positioned proximate to the concave edge 230 of the visor 210.

The connector bottom portion 320 can be spaced from the connector top portion 310 and positioned proximate to the visor bottom surface 240. In an embodiment the connector bottom portion 320 is oriented substantially parallel with the visor bottom surface 240. In an embodiment the connector bottom portion 320 is oriented substantially parallel with the connector top portion 310. The connector bottom portion 320 can have a connector bottom portion edge 321. The connector bottom portion edge 321 can be positioned proximate to the concave edge 230 of the visor 210. In an embodiment the connector bottom portion edge 321 and the connector top portion edge 311 are substantially equidistant from the concave edge 230.

The connector end portion 350 can extend between the connector top portion 310 and the connector bottom portion 320. In an embodiment the connector end portion 350 can extend from the connector top portion 310 to the connector bottom portion 320. The connector end portion 350 can be positioned proximate to the concave edge 230. The connector end portion 350 can extend substantially perpendicular between the connector top portion 310 and the connector bottom portion 320.

The connector back portion 340 can extend from proximate the concave edge 230 to adjacent the crown 410. In an embodiment the connector back portion 340 can extend from proximate the concave edge 230 to between the sweatband 450 and the crown 410. The connector back portion 340 can extend from the connector end portion 350 and away from the front edge 231. In an embodiment the connector back portion 340 can extend substantially perpendicular from the connector end portion 350.

Top adhesive 292 can be disposed between the visor top surface 220 and the connector top portion 310. The top adhesive 292 can be used to couple the connector top portion 310 to the visor top surface 220. Bottom adhesive 290 can be disposed between the visor bottom surface 240 and the connector bottom portion 320. The bottom adhesive 290 can be used to couple the connector bottom portion 320 to the visor bottom surface 240. Back adhesive 291 can be disposed between the concave edge 230 and the connector 300. The back adhesive 291 can be used to couple the connector 300 to the concave edge 230. The bottom adhesive 290, back adhesive 291, and the top adhesive 292 can comprise tape, glue, and other bonding adhesives.

The connector 300 maybe comprise of plastic, metal, composite, wood, and other materials that can be manufactured into the connector 300 shown.

A fastener 264 (sometimes referred to as a second fastener) can extend through the crown 410, the connector back portion 340, and the sweatband 450. The fastener 264 can couple the connector back portion 340 to the crown 410.

In an embodiment, the fastener 264 may be sewing thread. In other examples the fastener 264 can comprise other know fasteners such as mechanical fasteners, adhesives, heat or friction welding, laser bonding, or other fastening mechanisms.

FIG. 4 is a top view of the visor from FIG. 1 isolated away from the cap assembly. The visor 210 includes the concave edge 230 and the front edge 231. The concave edge 230 can have a first end 283 and a second end 284 opposite the first end 283. The visor 210 can have a first corner 281 and a second corner 282. The first end 283 and the second end 284 can be adjacent to the first corner 281 and the second corner 282 respectively. The concave edge 230 can extend from proximate the first corner 281 to proximate the second corner 282. The front edge 231 can extend from proximate the first end 283 of the concave edge 230 to proximate the second end 284 of the concave edge. The front edge 231 can be convex with respect to the visor 210. The front edge 231, the concave edge 230, the first corner 281, and the second corner 282 can define the shape of the visor 210.

FIG. 5 is a top view of an exemplary embodiment of a visor. Structures and features previously described in connection with earlier described embodiments may not be repeated here with the understanding that, when appropriate, that previous description applies to the embodiment depicted in FIG. 5 and following figures. Additionally, the emphasis in the following descriptions is on variations of previously introduced features or elements. Also, some reference numbers for previously descripted features are omitted from the drawing to provide additional visual clarity and readability of the drawing.

Where the drawing includes multiple instances of the same feature, for example fastening feature 252, the reference number is only shown in connection with one instance of the feature to improve the clarity and readability of the drawing. This is also true in other drawings which include multiple instances of the same feature.

A visor 212 can include a fastening feature 252. In an embodiment there can be a plurality of fastening features 252 spaced apart and can be space from and positioned proximately along the concave edge 230. In other words, the fastening features 252 are positioned to contour the concave edge 230. The fastening features 252 can be positioned at the first corner 281 and the second corner 282.

In an embodiment the fastening features 252 extend through the visor 212 and can be apertures. In an example the fastening features 252 extend part way through the visor 212 and can be depressions. The fastening features 252 can have a rectangular cross section with respect to the visor top surface 220. In other examples the fastening features 252 can have other cross-section shapes such as circular, elliptical, trapezoidal, triangular, or other combinations of curved and/or straight portions.

FIG. 6 is a top view of an exemplary embodiment of a visor. A visor 214 can include a visor top surface 224 disposed at the top face of the visor 214 and a fastening feature 254 extending along and proximate to the concave edge 230. The fastening feature 254 can extend from the front edge 231 proximate the first corner 281 to the front edge 231 proximate the second corner 282. The fastening feature 254 can continuously contour the concave edge 230. The fastening feature 254 can be a groove, depression, or channel.

FIG. 7 is a top view of an exemplary embodiment of a visor. A visor 216 can include fastening features 256. The fastening features 256 can have varying spacing between each other. The fastening features 256 can be circular shaped apertures through the visor 216.

FIG. 8 is a top view of the visor assembly from FIG. 1. The connector top portion 310 can extend along the visor top surface 220 adjacent to the concave edge 230 (shown on FIG. 4). The connector top portion 310 can extend from the first corner 281 (shown on FIG. 4) to the second corner 282 (shown on FIG. 4) and can contour the concave edge 230 (shown in FIG. 4).

The connector top portion edge 311 can be positioned between the concave edge 230 (shown in FIG. 4) and the front edge 231. The connector top portion edge 311 can extend from proximate the first corner 281 (shown on FIG. 4) to the second corner 282 (shown on FIG. 4) and can contour the concave edge 230 (shown in FIG. 4).

The connector end portion 350 can extend from proximate the first corner 281 (shown on FIG. 4) to the second corner 282 (shown on FIG. 4) and can contour the concave edge 230 (shown in FIG. 4).

The connector back portion 340 can extend from proximate the first corner 281 (shown on FIG. 4) to the second corner 282 (shown on FIG. 4) and can contour the concave edge 230 (shown in FIG. 4).

FIG. 9 is a sectional view of the visor assembly shown in FIG. 8 along line IX-IX from FIG. 8. The connector 300 from FIG. 3 is shown here with additional detail. The connector 300 and adhesives 290, 291, 292 are shown spaced from the visor 210 to provide visual clarity of the drawing. However the connector 300 contacts the adhesives 290, 291, 292, which contact the visor 210. Spaces shown between connectors and visors in other figures may also be for visual clarity and connectors and visors may be in contact with each other in the other figures.

The connector back portion 340 can be positioned substantially equidistant from the connector top portion 310 and the connector bottom portion 320. The connector back portion 340 can extend substantially perpendicular from the connector end portion 350 away from the concave edge 230.

FIG. 10 is a sectional view of an exemplary visor assembly. A visor assembly 201 can include the visor 210 and the connector 300. In an embodiment the visor 210 and the connector 300 can contact each other.

The connector top portion 310 can be disposed adjacent the visor top surface 220. The connector top portion 310 can be adjoined to the visor top surface 220 via top interface 272. The connector bottom portion 320 can be disposed adjacent the visor bottom surface 240. The connector bottom portion 320 can be adjoined to the visor bottom surface 240 via bottom interface 274. The connector end portion 350 can be disposed adjacent the concave edge 230. The connector 300 can be adjoined to the concave edge 230 via back interface 273.

Interfaces 272, 273, 274 may each adjoin the connector 300 to the visor 210 by ultrasonic welding, thermo-bonding, plastic welding, solvent welding, heat sealing, infrared welding, radio frequency welding, friction welding, induction welding, laser welding, or other bonding, welding, or connection methods.

In an example the connector 300 and the visor 210 can be one piece and made of the same parent material.

FIG. 11 is a sectional view of an exemplary visor assembly. A visor assembly 202 can include the visor 214 and a connector 302. The visor 214 includes the visor top surface 224 and a visor bottom surface 244. The connector 302 includes a connector top portion 312 that can be disposed adjacent the visor top surface 224. The connector top portion can include a connector top portion edge 313 and a connector top protrusion 332 disposed adjacent the connector top portion edge 313. The connector top protrusion 332 extends from the connector top portion 312 towards the connector bottom portion 322. In an example the connector top protrusion 332 extends from the front edge 231 (shown on FIG. 6) proximate the first corner 281 (shown on FIG. 6) to the front edge 231 proximate the second corner 282 (shown on FIG. 6) such that the connector top protrusion 332 aligns with the fastening feature 254 of the visor 214. In an embodiment the connector top protrusion 332 extends into the fastening feature 254.

The visor 214 can include a fastening feature 253 at the visor bottom surface 244, opposite from the fastening feature 254. The fastening feature 253 can extend along and proximate to the concave edge 230. The fastening feature 253 can extend from the front edge 231 proximate the first corner 281 to the front edge 231 proximate the second corner 282. The fastening feature 253 can continuously contour the concave edge 230. The fastening feature 253 can be a groove, depression, or channel.

The connector 302 can include a connector bottom portion 322 that can be disposed adjacent the visor bottom surface 244. The connector bottom portion 322 can include a connector bottom portion edge 323 and a connector bottom protrusion 333 disposed adjacent the connector bottom portion edge 323. The connector bottom protrusion 333 extends from the connector bottom portion 322 towards the connector top portion 312. In an example the connector bottom protrusion 333 extends from the front edge 231 (shown on FIG. 6) proximate the first corner 281 (shown on FIG. 6) to the front edge 231 proximate the second corner 282 (shown on FIG. 6) such that the connector bottom protrusion 333 aligns with the fastening feature 253 of the visor 214. In an embodiment the connector bottom protrusion 333 extends into the fastening feature 253.

FIG. 12 is a sectional view of an exemplary visor assembly. A visor assembly 204 includes a visor 212 and a connector 304. The connector 304 includes a connector top portion 314 that can include a connector top portion edge 315, and a connector top protrusion 334 disposed adjacent the connector top portion edge 315. The connector top protrusion 334 extends from the connector top portion 314 towards the connector bottom portion 324. In an example there are multiple connector top protrusions 334 that may be located proximate to and along the connector top portion edge 315 such that the connector top protrusions 334 line up with the fastening features 252 of the visor 212. In an embodiment the connector top protrusions 334 extends into the fastening feature 252. The connector top protrusion 334 can be shaped with a taper. The tapered shape of the connector top protrusion 334 can facilitate the mating of the visor 212 with the connector 304.

The connector 304 can include a connector bottom portion 324 that can include a connector bottom portion edge 325, and a connector bottom protrusion 335 disposed adjacent the connector bottom portion edge 325. The connector bottom protrusion 335 extends from the connector bottom portion 324 towards the connector top portion 314. In an example there are multiple connector bottom protrusions 335 that may be located proximate to and along the connector bottom portion edge 325 such that the connector bottom protrusions 335 line up with the fastening features 252 of the visor 212. In an embodiment the connector bottom protrusions 335 extends into the fastening feature 254. The connector bottom protrusion 335 can be shaped with a taper. The tapered shape of the connector bottom protrusion 335 can facilitate the mating of the visor 212 with the connector 304.

FIG. 13 is a sectional view of an exemplary visor assembly. A visor assembly 206 can include the visor 216 and a connector 306. The connector 306 can include a connector top portion 316 disposed adjacent the visor top surface 220. The connector top portion 316 can include a connector top portion edge 317. The connector 306 can also include a connector bottom portion 326 that is disposed adjacent the visor bottom surface 240. The connector bottom portion 326 can include a connector bottom portion edge 327.

The visor 216 can include the fastening feature 256 disposed proximate to the concave edge 230. The fastening feature 256 can extend through the visor 216. A mechanical fastener 295 can extend through the connector top portion 316 proximate the connector top portion edge 317 through the fastening feature 256 to through the connector bottom portion 326 proximate the connector bottom portion edge 327. The mechanical fastener 295 can be used to connect the connector 306 to the visor 216. The mechanical fastener 295 may comprise rivets, eyelets, sewing thread, screws, grommets, plastic inserts, and other common fasteners.

FIG. 14 is a sectional view of an exemplary visor assembly. A visor assembly 208 can includes a visor 210 and a connector 308. The connector 308 can include two separate pieces, a connector top piece 351 and a connector bottom piece 352. The connector top piece 351 can include a connector top portion 318, a connector top portion edge 319, and a first connector back portion 348 (sometimes referred to as the connector back portion). Top adhesive 292 can be disposed between the visor top surface 220 and the connector top portion 318. The top adhesive 292 can be used to connect the connector top portion 318 to the visor top surface 220. The connector bottom piece 352 can include a connector bottom portion 328, a connector bottom portion edge 329, and a second connector back portion 347 (sometimes referred to as the connector bottom portion). Bottom adhesive 290 can be disposed between the visor bottom surface 240 and the connector bottom portion 328. The bottom adhesive 290 can be used to connect the connector bottom portion 328 to the visor bottom surface 240. The top adhesive 292 and bottom adhesive 290 may comprise tape, glue, and other bonding adhesives. The first connector back portion 348 and the second connector back portion 347 may be disposed adjacent to each.

FIG. 15 is a sectional view of an exemplary cap assembly. A cap assembly 101 can include the visor assembly 208 and the crown assembly 401. The crown assembly can include the crown 410 and a sweatband 451. The sweatband 451 can be positioned proximate the base of the crown 410 at a first location and extend to partially within the crown 410 at a second location.

The first connector back portion 348 and the second connector back portion 347 can extend to and be positioned between the crown 410 and the sweatband 451.

A first fastener 262 can extend through the crown 410, the connector back portion 340, and the sweatband 450 at the first location. The second fastener 264 can extend through the crown 410, the connector back portion 340, and the sweatband 450 at the second location. In an embodiment, the first fastener 262, and the second fastener 264 may be sewing thread. In other examples the first fasteners 262 and second fasteners 264 can comprise other know fasteners such as mechanical fasteners, adhesives, heat or friction welding, laser bonding, or other fastening mechanisms.

FIG. 16 is a top view of an exemplary embodiment of a visor. A visor 217 can include a fastening feature 257. In an embodiment there can be a plurality of fastening features 257 spaced apart. The fastening features 257 can be spaced from and positioned approximately along the concave edge 230. In other words, the fastening features 257 are positioned to contour the concave edge 230. The fastening features 257 can be positioned at the first corner 281 and the second corner 282. In an embodiment there are seven fastening features 257. In other examples there can be one, two, three, four, five, six, eight, nine, ten, or more fastening features 257. In an embodiment the fastening features 257 can extend through the visor 217 as circular shaped apertures.

FIG. 17 is a top view of an exemplary embodiment of a visor. A visor 218 can include the fastening features 257. The visor 214 can include a visor bottom surface 247 and a visor step 259 extending into the visor 214 adjacent to the concave edge 230. The visor step 259 can extend along the concave edge 230. The visor step 259 can extend from the front edge 231 proximate the first corner 281 to the front edge 231 proximate the second corner 282. The visor step 259 can continuously contour the concave edge 230. The visor step 259 can be a groove, depression, or channel.

FIG. 18 is a sectional view of an exemplary visor assembly. A visor assembly 203 can include the visor 217 and a connector 305. The connector 305 can include a connector top portion 618 disposed adjacent the visor top surface 220. The connector top portion 319 can include a connector top portion edge 619. The connector 306 can also include a connector bottom portion 336 that is disposed adjacent the visor bottom surface 240. The connector bottom portion 336 can include a connector bottom portion edge 629. The connector 305 can include a connector end portion 350 and a connector back portion 344 (sometimes referred to as the first connector back portion).

The connector top portion 618 can include a connector top aperture 519 extending through the connector top portion 618. In an embodiment the connector top aperture 519 aligns with the fastening feature 257. The connector top aperture 519 can be positioned between the connector top portion edge 619 and the connector end portion 350. The connector top aperture 519 can be positioned proximate to the concave edge 230.

The connector bottom portion 336 can include a connector bottom aperture 529 extending through the connector bottom portion 336. In an embodiment the connector bottom aperture 529 aligns with the fastening feature 257 and can align with the connector top aperture 519. The connector bottom aperture 529 can be positioned between the connector bottom portion edge 629 and the connector end portion 350. The connector bottom aperture 529 can be positioned proximate to the concave edge 230.

The connector back portion 344 can include a first back portion 642 and a second back portion 644. The first back portion 642 can extend from the connector end portion 350 away from the connector bottom portion 336. In other examples the first back portion 642 can extend from the connector end portion 350 away from the connector top portion 319.

The second back portion 644 can extend from the first back portion 642. In an embodiment the second back portion 644 extend substantially perpendicular from the first back portion 642. In other example the second back portion 644 extends from the first back portion 642 at angles between perpendicular and parallel with respect to the first back portion 642.

The second back portion 644 can be oriented sustainably parallel with the connector end portion 350. The first back portion 642, the second back portion 644, and the connector end portion 350 can define and form a crown gap 650. The crown gap 650 can be sized to receive the base of the crown 410.

A mechanical fastener 296 can extend through the connector top aperture 519 through the fastening feature 257 to through the connector bottom aperture 529 proximate the connector bottom portion edge 327. The mechanical fastener 296 can be used to connect the connector 305 to the visor 217. The mechanical fastener 296 may comprise rivets, eyelets, sewing thread, screws, grommets, plastic inserts, and other common fasteners.

FIG. 19 is a sectional view of an exemplary visor assembly. A visor assembly 207 can include the visor 218 and a connector 309. The visor 218 can be thinner at the visor step 259 than away from the visor step 259.

The connector 309 can include a connector bottom portion 625 that is disposed adjacent the visor step 259. The connector bottom portion 625 can include a connector bottom portion edge 628. The connector 309 can include a connector back portion 346 (sometimes referred to as the first connector back portion).

The connector bottom portion 625 can include a connector bottom aperture 638 extending through the connector bottom portion 625. In an embodiment the connector bottom aperture 638 aligns with the fastening feature 257. The connector bottom aperture 638 can be positioned between the connector bottom portion edge 628 and the connector back portion 346. The connector bottom aperture 638 can be positioned proximate to the concave edge 230.

The connector back portion 346 can extend sustainably perpendicular from the connector bottom portion 625 proximate the concave edge 230.

The connector back portion 346, the connector bottom portion 625, and the concave edge 230 can define and form a crown gap 750. The crown gap 750 can be sized to receive the bottom edge of the crown 410.

FIG. 20 is a sectional view of an exemplary visor assembly. A visor assembly 205 can include the visor 219 and a connector 307. The visor 219 can include a visor top surface 227 opposite from the visor bottom surface 247. The visor top surface 337 located at the top face of the visor 219.

The visor 219 can be similar to visor 219 and can additionally include a second visor step 258. The second visor step 258 can be similar to the visor step 259 (sometimes referred to as the first visor step) and positioned at the visor top surface 227. The second visor step 258 can be substantially parallel with the first visor step 259.

The visor 219 can be thinner at the second visor step 258 and the first visor step 259 than away from the second visor step 258 and first visor step 259.

The connector 307 can include a connector top portion 616 disposed adjacent the second visor step 258 and the visor top surface 227. The connector top portion 616 can include a connector top portion edge 617. The connector 307 can also include a connector bottom portion 623 that is disposed adjacent the first visor step 259 and the visor bottom surface 247. The connector bottom portion 623 can include a connector bottom portion edge 626. The connector 307 can include a connector end portion 350 and a connector back portion 345 (sometimes referred to as the first connector back portion).

The connector top portion 616 can include a connector top aperture 627 extending through the connector top portion 616. In an embodiment the connector top aperture 627 aligns with the fastening feature 257. The connector top aperture 627 can be positioned between the connector top portion edge 617 and the connector end portion 350. The connector top aperture 627 can be positioned proximate to the concave edge 230.

The connector bottom portion 623 can include a connector bottom aperture 637 extending through the connector bottom portion 623. In an embodiment the connector bottom aperture 637 aligns with the fastening feature 257 and can align with the connector top aperture 627. The connector bottom aperture 637 can be positioned between the connector bottom portion edge 626 and the connector back portion 345. The connector bottom aperture 637 can be positioned proximate to the concave edge 230.

The connector back portion 345 can extend from the connector end portion 350 away from the connector bottom portion 336.

The connector 307 can include a connector bottom portion 623 that is disposed adjacent the visor step 259. The connector bottom portion 623 can include a connector bottom portion edge 626. The connector 307 can include a connector back portion 345.

The connector bottom portion 623 can include a connector bottom aperture 637 extending through the connector bottom portion 623. In an embodiment the connector bottom aperture 637 aligns with the fastening feature 257. The connector bottom aperture 637 can be positioned between the connector bottom portion edge 626 and the connector back portion 345. The connector bottom aperture 637 can be positioned proximate to the concave edge 230.

The connector back portion 345 can extend sustainably perpendicular from the connector bottom portion 625 proximate the concave edge 230.

FIG. 21 is a sectional view of an exemplary visor assembly. A visor assembly 209 can include the visor 217 and a connector 500. The connector 500 can include a connector top portion 510 disposed adjacent the visor top surface 220. The connector top portion 510 can include a connector top portion edge 511. The connector 500 can also include a connector bottom portion 520 that is disposed adjacent the visor bottom surface 240. The connector bottom portion 520 can include a connector bottom portion edge 521. The connector 500 can include a connector end portion 350 and a connector back portion 540 (sometimes referred to as the first connector back portion).

The connector back portion 540 can extend from the connector end portion 350 away from the connector top portion 510. In an embodiment the connector back portion 540 extends substantially perpendicular from the connector top portion 510 opposite from the connector top portion edge 511.

INDUSTRIAL APPLICABILITY

The present disclosure generally applies to visor assemblies 200, 201, 202, 203204, 205, 206, 207, 208, 209, and cap assemblies 100, 101 with visor assemblies 200, 201, 202, 203204, 205, 206, 207, 208, 209.

There are couple common methods used in industry to connect visors to crown assemblies to make caps and other headwear. The first common method of uses a visor, made of plastic or cardboard, that is placed into a fabric sleeve or pocket and creating a visor assembly having a portion where the fabric extends beyond the back of the visor to provide a sewable medium to connect the cap crown and the sweatband to the visor. This requires the visor to be covered with fabric and often time limits the visor material to materials that can be easy sewn through and visor shapes and materials that work well with a fabric sleeve/pocket over them. The second way involves using a visor made of sewable material. This allows the visor material to be visible, however the visor materials are limited to materials that are sewable and have the structural properties to endure a person wearing such a cap.

The connector back portion 340, 344, 345, 346, 347, 348, 540 can be made of a sewable material and can be sewn with the crown 410 and the sweatband 450. The connectors 300, 302, 303, 304, 305, 306, 307, 308, 309 can include features such as protrusions 332, 333, 334, 335, mechanical fasteners 295, 296, adhesives 290, 291, 292, and interfaces 272, 273, 274 that can be configured to mate with and/or connect with visors 210, 212, 214, 216, 217, 218, 219. The visors 210, 212, 214, 216, 217, 218, 219 can include features such as fastening features 252, 254, 256, 257, 258, 259 that facilitate the connection of the visors 210, 212, 214, 216, 217, 218, 219 to the connectors 300, 302, 303, 304, 305, 306, 307, 308, 309.

By incorporating the connectors 300, 302, 303, 304, 305, 306, 307, 308, 309 a wider variety of caps with visors of different shapes and materials can be manufactured and used in cap assemblies. For example materials such as wood, metal, plastics, and composites such as carbon fiber could be used for visors 210, 212, 214, 216, 217, 218, 219.

Although this invention has been shown and described with respect to detailed embodiments thereof, it will be understood by those skilled in the art that various changes in form and detail thereof may be made without departing from the spirit and scope of the claimed invention. Accordingly, the preceding detailed description is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention. Furthermore, there is no intention to be bound by any theory presented in any preceding section. It is also understood that the illustrations may include exaggerated dimensions and graphical representation to better illustrate the referenced items shown, and are not consider limiting unless expressly stated as such.

It will be understood that the benefits and advantages described above may relate to one embodiment or may relate to several embodiments. Aspects described in connection with one embodiment are intended to be able to be used with the other embodiments. Any explanation in connection with one embodiment applies to similar features of the other embodiments, and elements of multiple embodiments can be combined to form other embodiments. The embodiments are not limited to those that solve any or all of the stated problems or those that have any or all of the stated benefits and advantages.

Claims

1. A visor assembly, the visor assembly comprising: a visor having a visor top surface,a visor bottom surface,a concave edge extending between the visor top surface and the visor bottom surface, the concave edge having a first end, anda second end opposite the first end, anda front edge extending from adjacent the first end to adjacent the second end; anda connector having a connector top portion positioned adjacent to the visor top surface, the connector top portion having a connector top portion edge located proximate to the concave edge, the connector top portion edge extending from proximate the first end to proximate the second end,a connector bottom portion positioned adjacent to the visor bottom surface and spaced from the connector top portion, the connector bottom portion having a connector bottom portion edge positioned proximate to the concave edge, the connector bottom portion edge extending from proximate the first end to proximate the second end, anda connector back portion extending from proximate the concave edge and away from the front edge.

2. The visor assembly from claim 1, wherein the visor assembly further comprises a connector end portion extending between the connector top portion and the connector bottom portion and positioned adjacent to the concave edge.

3. The visor assembly from claim 2, wherein the connector back portion extends from adjacent the connector end portion.

4. The visor assembly from claim 1, wherein the connector back portion extends from the connector bottom portion.

5. The visor assembly from claim 1, wherein the connector top portion and the connector bottom portion substantially contour the concave edge.

6. The visor assembly from claim 1, wherein the visor has a fastening feature located proximate to the concave edge.

7. The visor assembly from claim 6, wherein the cap assembly further comprises a mechanical fastener extending through the connector top portion, the connector bottom portion, and the fastening feature.

8. The visor assembly from claim 6, wherein the connector top portion further includes a connector top protrusion extending from proximate the connector top portion edge into the fastening feature.

9. The visor assembly from claim 6, wherein the connector bottom portion further includes a connector bottom protrusion extending from proximate the connector bottom portion edge into the fastening feature.

10. A cap assembly, the cap assembly comprising: a crown;a visor having a visor top surface,a visor bottom surface,a first corner,a second corner,a concave edge extending between the visor top surface and the visor bottom surface, the concave edge extending from the first corner to the second corner, anda front edge extending from adjacent the first corner to adjacent the second corner; anda connector having a connector bottom portion positioned adjacent to the visor bottom surface, the connector bottom portion having a connector bottom portion edge positioned proximate to the visor concave edge, the connector bottom portion edge extending from proximate the first corner to proximate the second corner, anda first connector back portion extending from proximate the concave edge to between the sweatband and the cap crown.

11. The cap assembly from claim 10, wherein the first connector back portion extends from the connector bottom portion opposite from the connector bottom portion edge.

12. The cap assembly from claim 10, wherein the connector further comprises a connector top portion positioned adjacent to the visor top surface, the connector top portion having a connector top portion edge positioned proximate to the concave edge.

13. The cap assembly from claim 12, wherein the connector further comprises a second connector back portion extending from proximate the connector top portion to between the sweatband and the cap crown.

14. The cap assembly from claim 12, wherein the connector further comprises a connector end portion extending from the connector top portion to the connector bottom portion and positioned adjacent to the concave edge.

15. The cap assembly from claim 14, wherein the first connector back portion extends from the connector end portion.

16. A cap assembly, the cap assembly comprising: a crown;a visor having a visor top surface,a visor bottom surface,a first corner,a second corner,a concave edge extending between the visor top surface and the visor bottom surface, the concave edge extending from the first corner to the second corner, anda front edge extending from adjacent the first corner to the second corner; anda connector having a connector top portion positioned adjacent to the visor top surface,a connector bottom portion positioned adjacent to the visor bottom surface,a connector end portion extending from the connector top portion to the connector bottom portion and positioned adjacent to the concave edge, anda connector back portion extending from adjacent the connector end portion away from the concave edge.

17. The cap assembly from claim 16, wherein the visor has a fastening feature located proximate to the concave edge.

18. The cap assembly from claim 17, wherein the cap assembly further comprises a mechanical fastener extending through the connector top portion, the connector bottom portion, and the fastening feature.

19. The cap assembly from claim 17, wherein the connector top portion further includes a connector top protrusion extending into the fastening feature and wherein the connector bottom portion further includes a connector bottom protrusion extending into the fastening feature.

20. The cap assembly from claim 16, wherein the connector back portion further comprises a first back portion extending from the connector end portion, anda second back portion extending substantially perpendicular from the first back portion.