MOLDED LIGHTING DEVICE FOR USE ON APPAREL AND APPAREL ARTICLE HAVING SAME

Abstract

A lighting device for use on apparel includes a main body portion and a raised graphic portion at the front of the main body. Inside the device there is a graphic element in the raised portion that is translucent. Behind the graphic element and inside the main body of the device there is one or more lighting elements, a control circuit, and a battery. There is a power connector at a side of the main body, or in a remote connector, to charge the battery, and one or more switches either at the side of the main body or on the remote connector to allow a person to control the lighting operation of the device. The device is molded in the form of the graphic element and the graphic element, lighting element, battery, and circuitry are embedded in the molded body.

Claims

1. A lighting device, comprising: a body comprised of a cured moldable material; at least one graphical element disposed in the cured moldable material of the body at a front of the body; a circuit board disposed behind the graphical element in the cured moldable material of the body, at least one switch disposed on the circuit board, and a power connector disposed on the circuit board; wherein 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; a battery disposed in the cured moldable material of the body; 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; and wherein 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.

2. The lighting device of claim 1, wherein the cured moldable material is silicone.

3. The lighting device of claim 1, further comprising a patch of fastener material adhered to a back of the lighting device, opposite the front of the body.

4. The lighting device of claim 1, wherein the cured moldable material is transparent or translucent.

5. The lighting device of claim 1, wherein the graphical element has at least an opaque portion, and wherein the circuit board, battery, and at least one lighting element are not directly viewable from a front of the body due to being blocked from view by the opaque portion of the graphical element.

6. The lighting device of claim 1, wherein the body further includes a periphery that extends outward from the body around a perimeter of the body at a back side of the body.

7. The lighting device of claim 1, further comprising a light diffusing element positioned between the at least one lighting element and the at least one graphic element.

8. A hat, comprising: an exterior surface; a lighting device attached to the exterior surface, the lighting device having: 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; at least one graphical element disposed in the cured moldable material of the body in the raised portion; 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; 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; and 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; and wherein 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.

9. The hat of claim 8, wherein the lighting device is attached to the hat by stitching that passes through the main body portion.

10. The hat of claim 9, wherein the body further includes a periphery around a perimeter of a back side of the main body portion, and wherein the stitching passes through the periphery.

11. The hat of claim 10, further including a layer of material disposed in the cured moldable material of the body at a back of the main body portion and which extends into the periphery.

12. The hat of claim 11, wherein an inner side of the layer of material is reflective.

13. The hat of claim 8, wherein a remote connector is coupled to the lighting control circuit in the main body portion by wires, the remote connector being disposed in the hat remotely from the main body portion and including a power connector.

14. The hat of claim 13, wherein the remote connector includes a switch for control an operation of the at least one lighting element of the lighting device.

15. The hat of claim 8, further comprising a light diffuser positioned between the at least one graphic element and the at least one lighting element.

16. A method of making a lighting device for use on an apparel article, comprising: 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; placing the graphic element into the raised portion of the mold, the graphic element being translucent; placing at least one lighting element over the graphic element; placing a lighting control circuit into the mold that is operable coupled to the at least one lighting element; placing a battery in the mold that is operably coupled to the lighting control circuit and the at least one lighting element; 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.

17. The method of claim 16, further comprising providing a power connector that is operably coupled to the lighting control circuit and at least one switch that is operably coupled to the lighting control circuit and the battery.

18. The method of claim 16, wherein providing the mold further comprises providing the mold having a periphery around a perimeter of a top of the mold.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0028] The accompanying figures, where like reference numerals refer to identical or functionally similar elements throughout the separate views and which together with the detailed description below are incorporated in and form part of the specification, serve to further illustrate various embodiments and explain various principles and advantages all in accordance with the present invention.

[0029] FIG. 1A is a front view of a lighted accessory for use on apparel, in accordance with some embodiments.

[0030] FIG. 1B is a side elevational view of a lighted accessory, in accordance with some embodiments.

[0031] FIG. 1C is a front view of a baseball style cap having a lighted accessory on the front, in accordance with some embodiments.

[0032] FIG. 2 is a block schematic diagram of the electrical and electronic elements of a lighted accessory device, in accordance with some embodiments.

[0033] FIG. 3 is a more detail block diagram of circuit functions of a lighted accessory device, in accordance with some embodiments.

[0034] FIG. 4 is an exploded assembly view of a lighted accessory device, in accordance with some embodiments.

[0035] FIG. 5 is a downward view of the rear of a lighted accessory device in a mold, in accordance with some embodiments.

[0036] FIG. 6 is a rear view of a lighted accessory device including a layer of fastening material for attachment to an apparel article, in accordance with some embodiments.

[0037] FIG. 7 shows a back view of the lighted accessory device for use with an apparel article, in accordance with some embodiments.

[0038] FIG. 8 shows a front view of a hat on which a lighted accessory device has been sewn, in accordance with some embodiments.

[0039] FIG. 9 shows a side perspective view of a hat having a lighted accessory device, in which the control and power connector are located remotely in the hat from the lighted accessory device, in accordance with some embodiments.

DETAILED DESCRIPTION

[0040] 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.

[0041] FIG. 1A is a front view of a lighted accessory 100 for use on apparel, in accordance with some embodiments. The lighted accessory is a device that has, on its front, a raised graphic 104, such as, for example, lettering. The raised graphic 104 is raised relative to the main body 102 of the accessory 100, which also houses the circuitry, battery, light emitting elements, and light spreading/diffusing members. As shown here, the accessory 100 has a main body 102 on which is a graphic 104 in 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 body 102 of the accessory 100 is 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 body 102 so as to be accessible, either on a side of the main body 102 or in a remote portion via wires. The accessory is intended to be affixed or attached to an apparel item, such as a cap.

[0042] FIG. 1B is a side elevational view of a lighted accessory, in accordance with some embodiments. A portion of the accessory 100 at a side/edge of the accessory 100 is shown here. There is a portion of the main body 102, which includes a side having a height 108, and on which there is a raised graphic portion 104, which has a height 108 above the main body 102. Both the main body 102 and raised graphic 104 are 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.

[0043] FIG. 1C is a front view of a baseball style cap 110 having a lighted accessory device 100 attached on the front 112 of the cap, in accordance with some embodiments. The lighted accessory device 100 is 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 device 100 can be attached to the front 112 of the cap 110 such as by a layer of hook and loop type fastener material, having a layer on the back of the lighted accessory device 100 and a layer on the front 112 of the cap 100, in some embodiments. Alternatively, the lighting accessory device 100 can be more permanently attached to the cap 110, such as by sewing a periphery of the lighted accessory device 100 to the front 112 of the cap 110. The lighted accessory device 100 comprises a body 102 that 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.

[0044] 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.

[0045] FIG. 2 is a block schematic diagram 200 of the electrical and electronic elements of a lighted accessory device 100, in accordance with some embodiments. A circuit board includes lighting control circuitry 202 for controlling lighting elements 210, 212, that can each have multiple light emitting diodes 214 or similar light producing elements. The circuitry 202 can also control charging and current/voltage regulation of a battery 204. The lighting control circuitry 202 can be disposed on a circuit board, as are user controls that can include a button switch 206, and slide switch 208, and a power connector 216. In some embodiments the button switch 206 or the slide switch 208 may not be used. In some embodiments the slide switch 208 turns the lighting control circuitry 202 on/off, and the button switch 206 causes the lighting control circuit 202 to control the output of the lighting elements 210, 212 to cycle through different lighting patterns (e.g. constantly on, flashing, phasing between dim and bright). The connector 216 can be, for example, a micro-USB connector. The switches 206, 208, and connector 216 can be supported on the same circuit board as the lighting control circuitry 202, and can be positioned near an edge of the mold so that the switch 206, 208 and connector 216 extend 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 switch 208, button switch 206, and power connector 216 can be housed together in a remote housing structure, outside the main body 102 of the lighted accessory device 100, and coupled to the lighting control circuitry 202 via suitable wiring.

[0046] FIG. 3 is a more detail block diagram of circuit functions of a lighted accessory device 100, in accordance with some embodiments. There can be a power regulator circuit 302 that regulates power to the lighting elements (e.g. 210, 212). The lighting elements 210, 212 can comprises a plurality of light emitting diodes (LEDs). The power regulator 302 can be controlled by an LED controller 304, which can be responsive to the button switch 206 to cycle between lighting modes or patterns. The USB interface 306 allows power to be provided to recharge the battery, and can be connected to a USB connector at the side of the lighted accessory device 100, or on a remotely located structure coupled to the lighted accessory device via wiring.

[0047] FIG. 4 is an exploded assembly view of a lighted accessory device 400, in accordance with some embodiments. The lighted accessory device 400 can be substantially similar or the same as lighted accessory device 100 discussed previously. The view shows the elements, other than the body material, that are included in the device, and the mold 402 in which the elements are placed. The mold 402 has 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 portion 403 and a raised graphic portion 405. The electrical and other elements shown here are not shown to scale relative to the mold 402 as in the actual device being made all of the components represented here fit into the mold 402.

[0048] In general, the elements are loaded into and arranged in the mold 402, and then the moldable material is poured into the mold to fill the volume of the mold 402. Generally, one or more graphical elements 404 are first placed into the mold 402, and in particular into the raised section 405. The graphical elements 404 can 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 portion 405 in which the raised graphic portion (e.g., 104) is formed, and it forms the face of the device 400, so the graphical elements 404 will be at the front of the device 400 upon completion of the molding process. The graphical elements 404 can have retaining features 406 that couple to, and hold a circuit board 408 in place on the back of the graphical element 404.

[0049] The circuit board 408 has the majority of the circuitry disposed on the circuit board, including, for example one or more switches 410, and a power connector (not shown here) that are arranged on the circuit board to extend outside of the mold 402. A battery 412 can be disposed on the circuit board 408 or elsewhere behind the graphical element 404 but is otherwise wired to the circuit board 408. One or more lighting elements 414 are connected to the circuit board 408 via wiring 416 and controlled by circuitry on the circuit board 408. The lighting elements 414 can also be retained on the back of the graphical element 404 such as by additional retaining features such as 406 used to hold the circuit board 408 in place. In some embodiments a light diffusing element 407 can be placed between the lighting elements 414 and the graphical elements 404 to prevent the appearance of hot spots and diffuse the light emitted by the light emitting elements 414 across the graphical elements 404. The retaining features 406 can be clips or simply posts to align the battery, lighting elements, and circuit board.

[0050] The elements shown here and loaded in a vertical stack into the mold 402, 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 board 408 can be a flexible two-sided circuit board on which the lighting control circuitry and lighting elements 414, as well as the battery 412, and connectors/switches 410 can be mounted. As mentioned, it is intended that all of the elements shown here can be placed entirely in the mold 402 such 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 material 418 can then be affixed to the lighted accessory device, which can include a layer of reflective material 419 to reflect light towards the front of the lighted accessory device. The backside 421 of the material 418 can 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 section 420 around the top of the mold 402 that 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 material 418 can extend into the periphery 420 to strengthen to periphery region.

[0051] FIG. 5 is a downward view of the rear of a lighted accessory device 400 in a mold 402, in accordance with some embodiments. his view shows the elements in the mold 402 prior to pouring the moldable material. There is seen a graphical element 404 that is a stylized graphic depicting the word Miami as is seen in FIG. 1. On top of the graphical element 404 is the light diffuser elements 407, and on top of the light diffuser 407 is a circuit board 408 that includes a battery 412. A push button switch 410 is disposed on the circuit board 408, and extends, horizontally, outside of the mold 402 to ensure that a user can access and operate the push button switch 410. Likewise, a slide switch 512 is mounted on the circuit board 408 in a position that it also extends outside of the mold 402. And a power or micro-USB connector 514 is also disposed on the circuit board 408 and extends outside of the mold 402. The circuit board 408 includes circuitry for operating the lighting elements 414, that are wired to the circuit board 408, and which can include one or more light producing devices (e.g. LEDs). Retaining features 406 can extend from the back of the graphical element 404 and are positioned and configured to hold the circuit board 506 in place during the molding process. Similar features can be used for the lighting elements 414. Once the various components are arranged in the mold 402 as shown, a curable material is then poured into the mold 402, filling in spaces, and covering most, if not all of the components, leaving only the portions of the switches 410, 512, and power connector 514 that are outside of the mold exposed.

[0052] It will be appreciated that the graphic element 404 will fit only into the raised portion 405 of the mold, and the raised portion 405 will 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 elements 404 are simply translucent flat sections of material than, when looked at from the front, form the desired graphic. Thus, the material of the graphic element 404 can 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 diffuser 407 can 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 member 404). The retaining member 406 can pass through slots cut into the light diffuser 407, if necessary. Also, it will be appreciated that the cover element 418 is not shown here as it would cover and obscure the view of the other elements in the mold 402.

[0053] 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.

[0054] FIG. 6 is a rear view of a lighted accessory device 100 including a layer of fastening material 418 for attachment to an apparel article, in accordance with some embodiments. In this view the moldable material has been poured over the components shown in FIG. 5, and the poured material has been cured. Further, a patch of material 418 has been adhered on the cured material that allows the device 100 to be fastened onto apparel having a corresponding fastening material. The patch 418 can 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 patch 418 can simply be an opaque member prevents light from escaping at the back side of the device 100, and can include reflective material on the interior side (e.g., 419). The device 100 shown here can be the same as that shown in FIG. 1 attached to the hat, but it is shown from the rear here, before being placed onto the hat.

[0055] FIG. 7 shows a back view of the lighted accessory device 100 for use with an apparel article, in accordance with some embodiments. In this view, the periphery 420 is used to sew the device 100 to an apparel article, and there is no attachment material present on layer 418, such as hook/loop material. The inset shows a side view (rotated ninety degrees) to show the raised portion 104 and the main body 102 having a sidewall 702. The periphery 420 extends from the sidewall 702 at the back side of the device 100 around the perimeter of the device. Although not indicated here for the sake of clarity, the material 418 can extend to the outward perimeter of the periphery, as shown in the inset 704, in order to strengthen the periphery 420. FIG. 8 shows a front view 800 of a hat 802 on which a lighted accessory device 100 has been sewn, in accordance with some embodiments. Stitching 806 passes through the periphery 420 and the material of the hat, and holds the device 100 to the hat.

[0056] FIG. 9 shows a side perspective view of a hat 900 having a lighted accessory device 100, 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 connector 902 is coupled to the device 100 by wires 908, which can be, for example, a USB cable or equivalent. The wires 908 can pass through the material of the hat 900 in a location between the hat 900 and the back side of the device 100, and run along in the inside of the hat 900. Alternatively, in some embodiments, the remote connector 902 and wires 908 can be on the outside of the hat 900. In the inset 910 there is shown an end view 902a and a top view 902b of the remote connector 902. In the end view 902a the power connector 904 can be seen, along with the profile of the mode button 906, which can be substantially the same as the button switch 206. In the top view 902b the mode switch 906 is shown at the top surface. A power switch can also be included on the remote connector 902, or it can be located on the side of the device 100. The power connector 904 can be a common USB connector that allows charging of the battery. As shown, the remote connector 902 can be positioned at a side of the hat, but can also be positioned at other locations around the hat.

[0057] 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.

[0058] 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.