WO2010103511A1 - Waterproof audio system integrated into a cap - Google Patents

Abstract

The present invention provides a wearable waterproof and portable audio system that can be embedded in apparels and used as a music player. In a preferred embodiment of the invention the wearable waterproof and portable audio system of the invention is embedded in a cap arranged to provide a user-friendly interface employing control button(s), which can be used while performing a sport or any outdoor activity.

Description

WATERPROOF AUDIO SYSTEM INTEGRATED INTO A CAP

Field of the Invention

The present invention relates to wearable waterproof apparel comprising an integrated audio system. More particularly, the invention relates to a waterproof audio system embedded into a wearable cap and to a method for manufacturing the same.

Background of the Invention

Caps and portable music players are well known and popular. People who practice outdoor sports often use portable music players (e.g., iPod, MP3/4, and the like) to make their time more pleasant. One of the problems people face when listening to portable music players while practicing outdoor sports (such as jogging, running, riding bicycles, etc.) is placement and dislodging of the music player due to the outdoor activity. Handy player operations such as switching between audio tracks or adjusting the volume level may demand using both hands to do so and thus interrupt the outdoor activity. Common placements of music players, in an armband, inside sport shorts pocket or attached to the torso area using a clip, entails using long earphones wires, which in turn tend to disturb the natural body movement, enhance wear and tear of the headphone wires when stretched by erroneous movements/placement of the leads, or just dislodges the earpieces from the ears. People practicing outdoor sports often wear caps to protect themselves from sunlight. Keeping the portable music player on the cap is therefore a preferable combination. The patent literature discloses various devices that allow some connection between a cap and a portable music player, for instance, U.S. Pat. No. 5,881,160, issued to Sheppard, describes a cap placed over the head of the user having a tape playing apparatus secured to the crown of the cap and speakers placed near the ear openings of the wearer for playing desired tapes in a comfortable fashion while the wearer is sleeping. U.S. Pat. No. 5,410,746, issued to Gelber, discloses a headgear, such as a cap having a crown, a brim and an internal sweatband or flap, is combined with an electronic receiving device, such as a radio, which is connected to the inner surface of the flap by a first double sided adhesive strip. U.S. Pat. No. 5,034,995, issued to Ciccone, discloses a head supported portable radio assembly comprising an expandable rubber tubular headband that is worn around the head in combination with a self-contained miniature personal AM/FM stereo radio or mini cassette player. U.S. Pat. No. 5,510,961, issued to Peng, discloses a cap structure with sound recording and generating means and warning lights which includes digitalized sound recording and releasing means and light emitting diodes assembled on the visor of the cap. U.S. Pat. Application No. 2006/0072067, of Jannard, describes an eyewear retention system, which may include any of a variety of electronics, including telecommunications receivers, transmitters, electronic storage devices, and head-up display driving circuitry. U.S. Pat. No. 7,618,260, issued to Daniel, describes a wearable modular interface strap device for supporting multiple module units comprising a flexible strap with a plurality of electrically connected nodes acting as docking points to serial bus interface and mechanically connects removable modules. Ixoundwear company offers sport caps with a pocket for iPod (a portable music player http://www.ixoundwear.com/) .

The above-mentioned solutions fail to provide a complete and full product that offers a user-friendly flexible waterproof music player along with a light-weighted, wearable, comfortable common-looking cap.

It is therefore an object of the present invention to provide a wearable waterproof audio system and a method for manufacturing the same.

It is another object of the present invention to provide a waterproof audio system arrangement that can be embedded in a cap thereby providing a lightweight wearable audio system.

It is a further object of the present invention to provide a wearable waterproof audio system that is relatively flexible and having a relatively thin profile.

It is yet another object of the present invention to provide a waterproof audio system arrangement that can be easily and conveniently controlled utilizing distributed control means.

It is yet a further object of the present invention to provide a wearable waterproof audio system arrangement that can be conveniently used for playing and listening to audible content during sport or any outdoor activity.

Other objects and advantages of the invention will become apparent as the description proceeds. Summary of the Invention

The present invention provides a wearable waterproof and portable audio system that can be embedded in apparels and used as a music player. In a preferred embodiment of the invention the wearable waterproof and portable audio system of the invention is embedded in a cap (also referred to herein as an audio cap) to provide a lightweight audio player system that is comfortable to wear and easy to operate, and which overall appearance and weight are of a common cap. The audio cap embodiment of the invention is arranged to provide a user- friendly interface and experience allowing a user to conveniently listen to played audio content and operate the audio system embedded therein by means of handy control button (s) , which can be used while performing a sport activity such as walking, running or riding a bicycle with minimal interruption to the sports activity.

The audio cap embodiment of the invention further provides a waterproof music player protected from sweat and which can be used for practicing both indoors and outdoors sports while listening to music, or any other audible content, under all weather conditions and even in a water ambient (such as windsurfing or any other seaside sports) . It should also be appreciated that an important feature of the audio cap of the invention is that it is washable, thus permitting the user to clean the audio cap after being used in outdoor/sport activities by means of water and soap.

According to one aspect the present invention is directed to a wearable waterproof audio system embedded in a cap comprising memory storage means embedded in audio player means (also referred to herein as audio system) electrically linked to a power source, preferably a rechargeable power source, said audio player means is configured to be connected to external data and/or electric charging systems for managing the content stored in its memory storage and/or for charging its power source. The audio player means further comprises an earphones connector for connecting earphones, or any other audio outputting means (e.g., speakers), thereby allowing it to play audio content stored in its memory. In a preferred embodiment of the invention, the audio system is adapted to transfer digital data and charge the power source by means of universal serial bus (USB) connectivity, such that it may be connected to any personal computer for the purpose of copying/deleting files to/from its memory and/or charging its power source, without needing additional cables or any hardware accessories.

According to one preferred embodiment of the invention the waterproof audio system is made substantially flexible and thin (e.g., the audio player and its power source having thicknesses of approximately 1.5 to 5 mm) for allowing it to be embedded in a reinforcing stiffening member of a cap visor. The core components of the audio player means are preferably implemented by a PCBA circuitry comprising processing means and memory means (e.g., RAM, ROM, EEPROM) for storing program code and other data used by the processing means for operating the audio system and memory means for storing the audio content (e.g., Flash memory) . The PCBA circuitry may further comprise one or more LED(s) for providing indications regarding the operation (e.g., Play, pause, on/off, and the like) of the audio system. The power source is preferably a rechargeable power source electrically connected to the PCBA circuitry. Advantageously, the power source, the PCBA circuitry, and the wires electrically connecting them, are coated by one or more isolating layer (s) (e.g., by means of a type of silicone gel/glue). One or more additional isolating layer (s) are preferably further applied to cover the power source the PCBA circuitry and the wires electrically connecting them and portions of the reinforcing stiffening member surrounding the PCBA circuitry and the power source.

The visor reinforcing stiffening member may comprise dents adapted to receive the PCBA circuitry and the power source electrically connected to it. In such embodiments the one or more additional isolating layer (s) applied over the PCBA circuitry and the power source after they are attached to the visor reinforcing stiffening member (e.g., by glue) are preferably applied to further cover the boundaries of the dents .

One or more control button (s) adapted to operate the audio player means may be provided on the visor of the cap and/or on one of its closing straps. In one specific preferred embodiment of the invention the one or more control button (s) are placed on one of the closing straps, an earphones connector electrically linked to the audio player means is provided in the free end of the closing strap which allows a user to connect earpieces and listen to played audible content, and a USB connector electrically linked to the audio player means is provided in the free end of the other closing strap allowing a user to connect the audio system to any data/charging system (e.g., PC) for adding/removing data (e.g., audible content) and/or for recharging the power source . According to another specific preferred embodiment of the invention the one or more control button (s) are spread about the external rim of the visor over the location of user's eyes, when worn by a user. Most preferably, the audio player means and its control button (s) and power source are attached over the bottom side of the visor reinforcing stiffening member to allow direct line of sight between the LED(s) provided in the PCBA circuitry and the user's eyes, and providing direct lines of sight between the control button (s) and the user's eyes for comfort and ease of operation.

The audio cap of the invention preferably further comprises a pouch provided in the rear side of its crown for placing the earphones during time periods wherein the audio system is not used, and/or for placing other items (e.g., keys) . In yet another specific preferred embodiment of the invention the earphones connector and the USB connector are maintained in the pouch for ease and comfort of operation and for protecting them during the time periods in which they are not used.

According to another preferred embodiment of the invention the earphones connector and the USB connector are embedded into a single integrated connector unit, thus allowing convenient passage of the electric wires from the PCBA circuitry to the rear side of the cap in a single strand of wires. Advantageously, the integrated connector unit is arranged such that the earphones connector and the USB connector are substantially perpendicular to each other, such that the terminals of the earphones connector and of the USB connector may protrude outwardly therefrom via adjacent sides of the connector unit. Optionally, the audio player means, the power source and the one or more control button (s) may be embedded completely- inside the visor reinforcing stiffening member by means of a plastic molding process thereby sealing and providing waterproof protection to the audio system and, the power source and the one or more control button (s) . Alternatively, the audio player means, power source and one or more control button (s) are embedded completely inside the visor reinforcing stiffening member by means of a plastic lamination process, wherein said plastic lamination is sealed to water and protects the audio system, power source and one or more control button (s) .

The audio cap may further include clips above the ear area of the user for holding earphones wires . Additionally or alternatively, the power source may be charged by means of photovoltaic cells integrated in the cap.

The one or more control button (s) may comprise one or more of the following elements: dome switches, variable resistors, micro switches, micro joystick switches, and/or scroll wheel buttons. Additionally or alternatively, one or more control button (s) may be embedded in the crown portion of the cap.

Optionally, the audio cap may further comprise display means embedded in the cap, such as but not limited to, light emitting diodes (LEDs) display, liquid crystal display (LCD) , electronic paper (e-paper) , projection display. Additionally, wireless communication hardware (e.g., cellular communication means) may be embedded in the audio cap. By way of example, a Blue-tooth module and a microphone may be embedded in the Audio cap of the invention for allowing a user to receive incoming phone calls from a cellular phone having such blue- tooth support, by means of the audio cap.

Advantageously, the earphones may be waterproof earpieces which may have a short wire. Alternatively, the audio cap may comprise small waterproof speakers embedded inside the cap.

According to another aspect the present invention is directed to a method for manufacturing a wearable waterproof audio system embedded in a visor of a cap, the method comprising:

Providing a reinforcing stiffening member of a visor and applying glue over bottom surface areas wherein core components of the audio system are to be placed;

Providing a PCBA circuitry comprising memory and data processing means, said PCBA circuitry is electrically connected to a rechargeable power source, control buttons, and electrical wires used for connecting it to external data systems and/or electric charger (e.g., a personal computer);

Covering said PCBA circuitry, said rechargeable power source, and the connection of said electrical wires to said PCBA circuitry with one or more isolating layer (s);

Attaching said PCBA circuitry, rechargeable power source, control buttons and a section of said electrical wires to said reinforcing stiffening member;

Optionally applying one or more isolating layer (s) over said PCBA circuitry and rechargeable power source such that portions of the reinforcing stiffening member surrounding said PCBA circuitry and rechargeable power source are also covered with said one or more isolating layer (s);

Attaching an audio jack and a USB connector to said electrical wires; and Enclosing said reinforcing stiffening member in a visor of a cap and passing the electrical wires through the crown of the cap towards its rear side.

The method may further comprise providing a pouch in the crown of the cap. Advantageously, the earphones and USB connectors may be placed in the pouch of the cap. Additionally or alternatively, the earphones and USB connectors are integrated into a single connector unit.

Brief Description of the Drawings

The present invention is illustrated by way of example in the accompanying drawings, in which similar references consistently indicate similar elements and in which:

- Fig. IA is a side view of an audio cap of the invention comprising an audio system assembly, wherein the audio cap is placed on a user's head such that the visor of the cap is situated over the user's forehead;

- Fig. IB is a side view of the audio cap shown in Fig. IA wherein the cap is placed on the user's head such that the visor of the cap is situated over the user's nape;

- Figs. 2A to 2C show back views of possible embodiments of the audio cap of the invention having an audio jack embedded in it one of the closing straps, wherein Fig. 2A shows the cap closing straps in a closed state, Fig. 2B shows an embodiment of the invention wherein the closing strap comprises embedded control means, and Fig. 2C shows an embodiment of the invention wherein one of the closing straps comprises a USB connector; - Fig. 3 is a back perspective view of a preferred embodiment of the invention having earphones connecting means embedded in the closing strap of the audio cap;

- Figs. 4A and 4B show bottom views of a preferred embodiment of the audio cap of the invention, wherein Fig. 4A shows a possible arrangement of the audio system and its wiring and Fig. 4B shows a bottom perspective view of the audio cap when placed on a user's head;

- Figs. 5A to 5C schematically illustrates a preferred process for assembling the audio system and control means of the invention in a visor of a cap, wherein Fig. 5A shows a bottom view of the visor reinforcing stiffening member, Fig. 5B shows a bottom view of the visor reinforcing stiffening member with the components of the audio system placed therein, and Fig. 5C shows a bottom view of the vis.or reinforcing stiffening member with the audio system components after securing them with a water proof layer to the visor; and

- Figs. 6A to 6D illustrate integration of a standard audio and USB connectors into an integrated connector unit according to a preferred embodiment of the invention, wherein Fig. 6A shows a perspective view of the audio connector, Fig. 6B shows a perspective view of the USB connector, Fig. 6C shows a sectional view of the integrated connector unit illustrating arrangement of the audio jack and USB connectors, and Fig. 6D shows a perspective view of the integrated unit comprising both connectors.

It should be noted that the embodiments exemplified in the Figs, are not intended to be in scale and are in diagram form to facilitate ease of understanding and description. Detailed Description of Preferred Embodiments

The commonly manufactured baseball style cap generally consists of a fabric cap having a crown, a visor extending from the crown, an inner sweat band extending around the circumference of the cap and closing straps at the rear of the cap used for closing and fitting the cap over the user's head. The crown can be made of various types of fabrics (e.g., cotton, polyester, spandex, etc.) . Common practice is to place team and/or corporate company logos on the cap crown. The visor is usually constructed of fabric reinforced with an inner plastic stiffener layer.

With reference to the drawings, Figs. 1 to 6 depict preferred and alternative embodiments of the present invention, generally referred to herein as an audio cap assembly and referenced by numeral 10.

Figs. IA and IB depicts one preferred embodiment of an audio cap assembly 10 of the invention in two common ways of wearing it on a head of a user 40. More particularly, in Fig. IA the audio cap assembly 10 is worn such that the visor 11 is facing forward (i.e., the visor is situated • over the user's forehead) and in Fig. IB the visor is facing backward (i.e., it is situated over the user's scruff) . As shown, audio cap assembly 10 may comprise a crown 12 and it is electrically linked to earphones 30 used for playing audio content to the user.

Figs. 2A-2C show rear views of possible embodiments of the audio cap assembly 10 of the invention, wherein there is seen pouch 13 that is used for storing the earphones 30 when audio cap assembly 10 is not used for playing audio content. According to one preferred embodiment of the invention pouch 13 may further accommodate connecting means (shown in Figs. 6A to 6C) suitable for connecting earphones 30 to audio cap assembly 10, and for connecting audio cap assembly 10 to external data and/or electric charging system, as commonly employed with standard portable media players (e.g., MP3, MP4, iPod) utilizing standard universal serial bus (USB) connectivity (e.g., by connecting the audio player to a personal computer - PC) . In Fig. 2A audio cap assembly 10 is shown with its rear closing straps 15a and 15b in a closed state. Closing straps 15a and 15b are used for fitting and securing the audio cap assembly 10 over the user's head.

With reference to Figs. 2B and 2C, according to one preferred embodiment of the invention audio jack 26 may be embedded in closing strap 15a, and a USB connector 25 may be embedded in closing strap 15b. Fig. 2B further exemplifies an alternative embodiment in which additional control button (s) 24 are embedded in closing strap 15a. Control button (s) 24 may be implemented, for example, by a type of dome switch buttons or by a type of micro switches 24a-24c used for controlling the operation of the audio cap assembly. For example, buttons 24 may include a play/pause button 24b, a next track button 24c, a previous track button 24a, and a variable resistor slider 24d used for adjusting the audio volume of the played content. Additional button (s) 24 can ease operation of the audio cap 10 while it is used as depicted in Fig. IB when the visor 11 is facing backward. The connectivity of audio jack 26 and USB connector 25 may be achieved by means of electrically conducting wires (e.g., 27 and 28 as exemplified in Fig. 4A) passed through the straps 15a and 15b and/or the fabric of crown 12. Fig. 3 depicts the audio cap assembly 10 from a rear perspective view, showing the pouch 13 used for storing the earphones 30. Pouch 13 can be sewed outside or inside the audio cap crown 12, or on top of visor 11. For example, pouch 13 can be closed by a zipper, a button, a magnet or Velcro, and can store along with the earphones 30 some small objects such as small change. Earphones 30 may comprise a standard audio male connector 31 which fits in the audio jack 26 embedded in closing strap 15a, and audio wires 32 which can be held by the lateral clips 14a and 14b. Side clips 14a and 14b can be made from plastic or fabric and are employed for holding the earphone wire 32 in certain occasions, such as when the audio cap assembly 10 is being worn as depicted in Fig IB. Earphone wires 32 are preferably substantially shorter than common earphone wires since the distance between the audio jack 26 and the ears of the user (40) is much shorter than that required with standard media players, however, audio jack 26 is preferably a standard 2.5mm or 3.5mm audio jack and can be used to connect with any standard earphones.

Figs. 4A and 4B illustrate another preferred embodiment of audio cap assembly 10' having control press or touch buttons 23 distributed along the external rim Hr of visor 11. Fig. 4A depicts a bottom section view of the audio cap assembly 10", showing one preferred arrangement of the audio system assembled in cap 10'. The audio system is preferably comprised of separate electronic components which may comprise LED(s) 21, press or touch button (s) 23, a flat thin rechargeable power source 22 (e.g., Li Polymer Rechargeable Battery of AEenergy) wired to the PCBA (printed circuit board assembly) 20. PCBA 20 is preferably a flat and flexible PCBA circuitry designed for a portable music player according to specifications and standards known in the electronic industry, such that it may be embedded along with power source 22 inside, or on visor 11, preferably on its reinforcing plastic stiffener. In a particular preferred embodiment of the invention the thickness of PCBA circuitry 20 is made about 0.5 mm to assure appropriate flexibility features, these features can be obtained following media players' applications notes, as known in the art.

PCBA 20 typically comprise processing means (20s in Fig. 5B) and one or more memories (RAM, ROM or EEPROM - 2Op in Fig, 5B) for storing and executing device operating code, and in particular a memory storage suitable for storing audio content, such as a flash memory. PCBA 20 is connected by means of electrical wires 28 passing through visor 11 and crown 12 to the audio jack 26, and it may be also connected by means of electrical wires 27 (e.g., USB shielded wires) passing through visor 11 and crown 12 to USB connector 25. As seen, electrical wires 27 and 28 may be passed through opposing sides of crown 12 in order to eliminate passage of excessive electrical wires and for uniformly arranging the audio system components in cap 10. Preferably, electrical wires 27 and 28 are passed as a single wire strand through the crown of the audio cap.

Audio wires 28 and USB wires 27 are preferably covered with an isolating layer suitable for providing both electrical and water proof isolation (e.g. PVC plastic) . Audio wire 28 and USB wires 27 are preferably sewed between the sweat band (not shown) and the crown 12 fabric. USB connector 25 is used to connect audio cap assembly 10' to a PC, using the PC's USB port. Connecting audio cap assembly 10' to a PC allows the user to copy files to the memory storage inside PCBA 20 and also allows charging the power source 22 when a rechargeable power source is used. Fig. 4B depicts a bottom perspective view of the audio cap assembly 10', being worn by a user 40. The audio cap visor 11 is facing forwards and the button (s) 23 can be easily accessed by the user 40. In this preferred embodiment, button (s) 23 are placed in a layout, dividing the button (s) 23 into three groups: (i) audio play/truck control buttons 23a, 23b and 23c, arranged on top of the left eye of user 40 for providing convenient control over the play/pause (23b) , next track (23a) and previous track (23c) selection commands; (ii) audio volume control buttons 23d and 23e arranged on top of the right eye of user 40 for providing convenient control over the increase volume (23d - also marked by "+" symbol) and decrease volume (23e - also marked by "-" symbol) commands; and (iii) a reset button 23f (or on/off button) located near the right eyebrow of user 40. Buttons 23d and 23e give user 40 convenient control over the volume of the played audio content, and possibly also over equalizers functions which may be implemented by PCBA circuitry 20. Button 23f is preferably a reset button.

The LED(s) 21 are preferable located more or less between the eyes of user 40 for conveniently providing indications concerning the operation of the audio cap assembly 10. For example, blinking in one LED while playing an audio content and blinking another LED to indicate a state of low power of power source 22.

Figs. 5A to 5C schematically illustrate a method for arranging the audio system of the invention in a visor of a cap according to a preferred embodiment of the invention. With reference to Fig. 5A, the reinforcing stiffening member 11s of the visor is prepared to receive the core components of the audio system by applying glue (e.g. double-sided glue tape) onto areas 35 wherein the audio system core components are to be disposed.

The reinforcing stiffening element 11s is preferably made from a curved thin piece of material having some elasticity, as commonly used in caps, which may be manufactured for example from PVC or ABS plastics. Optionally, but not necessarily the reinforcing stiffening element 11s may comprise dents and grooves formed on surface areas of its bottom side designed for receiving components of the audio system, for example, dent 22g may be prepared for receiving the power source, dent 2Og for receiving the PCBA circuitry, and a suitable dent 19g for receiving the electrical wires used for connecting the core components of the audio system to the audio jack and the USB connectors. Additionally, a fastening snap (not shown) may be attached or formed at the side(s) of each dent for holding the core components 37 of audio system in place, with or without using adhesive means (e.g., glue) .

Fig. 5B illustrates placement of the audio system core components 37 over the respective areas 35 covered with glue. In this example the core components 37 are electrically connected and arranged to fit in their locations according to the cap design. Advantageously, before attaching core components 37 assembly to reinforcing stiffening member 11s it is dipped in a liquid coating material (e.g., Dow corning 3- 1953 or 1301ELO coating) for at least covering the power source 22 and the PCBA circuitry 20 with an isolating layer, and then left to dry.

Next, as illustrated in Fig. 5C, after placing power source 22, PCBA circuitry 20 and electrical wires 19 in their respective locations on reinforcing stiffening member 11s an isolating layer 22y is applied over the top side of power source 22 and an isolating layer 2Oy over the top side of PCBA circuitry 20, said isolating layer may be made of silicone (e.g., Gelle GO-1132L-1) . An isolating layer is preferably also applied over the wires 19s at their electrical attachments to PCBA circuitry 20, and optionally also over a substantial length of electrical wire 19.

As shown in Figs. 5B and 5C, control buttons assemblies 38a and 38b are electrically and physically attached to PCBA circuitry 20 and laterally extending therefrom on opposing directions adjacent the rim of reinforcing stiffening member 11s of the visor. Control buttons assemblies 38a and 38b are arranged such that their respective control buttons 23a 23b 23c (next track, play and previous track buttons) are provided at one side of the visor, and control buttons 23d and 23e (volume "+" and "-" buttons) are provided at the other side of the visor. In this preferred embodiment a reset button 23f ' is attached to PCBA circuitry 20 adjacent thereto more or less in the center of the visor. Control buttons assemblies 38a and 38b, reset button 23f ' and electrical wires 19 may be attached to reinforcing stiffening member 11s by glue, using the isolating material provide on PCBA circuitry 20 and power source 22, or simply by means of an adhesive tape.

In one preferred embodiment of the invention control buttons assemblies 38a and 38b are implemented utilizing dome switches attached to a flexible printed circuit board (FPC) and covered by one or more isolating waterproof layers. For example, the dome switches and FPC assemblies is optionally made waterproof by coating the assemblies with plastic adhesive tape layers (e.g., insulating sellotape) from both sides (e.g., enclosing each assembly by two adhesive tape strips) and then dipping the coated assemblies in a liquid coating material (e.g., Dow corning 3-1953 or 1301ELO coating) .

Figs. 6A to 6D illustrate connector assembly used in one preferred embodiment of the invention to conveniently integrate the audio jack 61 and USB connector 60 into a single connector unit 62. It is noted that this unique connector assembly simplifies the manufacture of the audio cap of the invention and also reduce manufacture costs, and is more convenient for the users to operate since the connectors of the audio system are provided in one connector unit. As will be appreciated this integrated connector settings allows using both USB and audio plug without having to disconnect either of them.

Fig. 6A shows a perspective view of audio jack 61 having a flange 61f near its female terminal 61i, and wires hole 61w at its other end. Fig. 6B shows a perspective view of USB connector 60 implemented employing a rectangular piece of printed circuit board having a lateral slit 60s, electrically conducting pads 6Og electrically linked to electrical wire connecting pads 6Ow. The electrically conducting pads 6Og are preferably provided adjacent one end of the rectangular piece of printed circuit board to implement the USB connecting pads while the slit 60s and the electrical wire connecting pads 6Ow are provided in opposing sides adjacent the other end of the printed circuit board.

Fig. 6C shows a sectional view of integrated connector unit 62 illustrating the arrangement of audio jack 61 and USB connector 60 therein. As seen, integrated connector unit 62 is having a more or less rectangular shape and it comprises a flexible wire holding structure 62w formed or attached at one of its sides, a rectangular groove 62u having an interlocking tab 62g formed in it for receiving and holding USB connector 60 such that interlocking tab 62g is fitted into slit 60s and conducting pads 6Og protrude laterally via another side of connector unit 62, and a cylindrical groove 62j having a circular channel 62f adapted to receive audio jack 61 such that its flange 61f is received in said circular channel 62f and its female terminal 61i protrudes laterally via yet another side of connector unit 62.

As seen, rectangular groove 62u and cylindrical groove 62j are arranged such that the elongated axes of USB connector 60 and audio jack 61 are substantially perpendicular to each other, thereby having their terminal protruding via adjacent sides of integrated connector unit 62. Fig. 6D shows a perspective view of integrated connector unit 62 with USB connector 60 and audio jack 61 assembled in it.

As will be appreciated by those skilled in the art integrated connector unit 62 is also advantageous as it allows to combine the electrical wires (19) from PCBA circuitry (20) and pass them as a single wire strand from the visor of the cap to its rear side wherein the integrated connector unit 62 resides. According to one preferred embodiment of the invention the electrical wires (19) connected to PCBA circuitry (20) are passed through the crown (12) of the cap into its pouch (13) in which integrated connector unit 62 is situated.

Of course, the pouch may be used for holding other items, such as keys, small change, and the like. It is noted that audio caps embodiments described hereinabove do not require any additional cables or accessories such that it may be operated simply by wearing the audio cap on the user's head, placing the earphones in the user's ears and playing a selected content. In specific preferred embodiments the audio cap may advantageously be designed to be heat proof by suitable selection of its components, thereby allowing it to withstand substantially high heat conditions (e.g., up to 70 degrees Celsius), which is beneficial for outdoor activities.

The above examples and description have of course been provided only for the purpose of illustration, and are not intended to limit the invention in any way. As will be appreciated by the skilled person, the invention can be carried out in a great variety of ways, employing more than one technique from those described above, all without exceeding the scope of the invention.

Claims

1. A wearable waterproof audio system embedded in a cap comprising a visor, a crown, and thin audio player means electrically linked to a thin rechargeable power source, said audio player means comprising processing means and memory means, wherein said audio player means, said rechargeable power source, and electric wires connecting them are covered with an isolating layer and attached to a reinforcing stiffening member provided in said visor, and wherein said audio player means is further provided with electrical connecting means for earphones, and for transferring digital data and for charging the power source.

2. The wearable waterproof audio system according to claim 1 wherein the audio player means is a PCBA circuitry comprising the processing means and the memory means.

3. The wearable waterproof audio system according to claim 1 wherein the audio player means and the power source are attached over the bottom side of the visor reinforcing stiffening member.

4. The wearable waterproof audio system according to claim 1 or 3 further comprising one or more LED(s) for providing indications regarding the operation of the audio player means.

5. The wearable waterproof audio system according to claim 1 or 3 wherein the reinforcing stiffening member comprises dents adapted to receive the audio player means and the power source electrically connected to it.

6. The wearable waterproof audio system according to claim 1 or 5 comprising additional isolating layers applied over the PCBA circuitry, over the power source, and over portions of the reinforcing stiffening member surrounding them.

7. The wearable waterproof audio system according to claim 1, 3 or 6 further comprising one or more control button (s) electrically linked to the audio player means adapted to operate the audio system.

8. The wearable waterproof audio system according to claim 7 wherein the one or more control button (s) are placed in the visor of the cap and/or on one of its closing straps.

9. The wearable waterproof audio system according to claim 7 wherein the one or more control button (s) are placed on one of the closing straps, and wherein the electrical connecting means comprise an earphones connector electrically linked to the audio player means, said earphones connector is placed in the free end of said one of the closing strap, and a USB connector electrically linked to the audio player means, said USB connector is placed in the free end of another closing strap of the cap.

10. The wearable waterproof audio system according to claim 7 wherein the one or more control button (s) are spread over the bottom side of the visor about its external rim.

11. The wearable waterproof audio system according to claim 10 wherein some of the control buttons are arranged in two groups which locations corresponds to the locations of user's eyes for improved visibility.

12. The wearable waterproof audio system according to any one of claims 1 to 11 further comprising a pouch provided in the rear side of the crown

13. The wearable waterproof audio system according to claim 12 wherein the electrical connecting means are standard earphone and USB connectors electrically linked to the audio player means, wherein said earphone and USB connectors are situated in the pouch of the cap.

14. The wearable waterproof audio system according to any one of claims 1 to 8, or 10 to 13 wherein the electrical connecting means are standard earphone and USB connectors electrically linked to the audio player means, wherein said standard earphone and USB connectors are embedded in a single integrated connector unit.

15. The wearable waterproof audio system according to claim 14 wherein the earphone and USB connectors are arranged substantially perpendicular to each other, such that their terminals protrude via adjacent sides of the connector unit.

16. The wearable waterproof audio system according to claim 1 wherein the audio player means, the power source and the one or more control button (s) are embedded inside the visor reinforcing stiffening member by a plastic molding process.

17. The wearable waterproof audio system according to claim 1 wherein the audio player means, the power source and the one or more control button (s) are embedded inside the visor reinforcing stiffening member by means of plastic lamination process .

18. The wearable waterproof audio system according to claim 1 further comprising clips above the ear area of the user for holding earphones wires.

19. The wearable waterproof audio system according to claim 1 further comprising photovoltaic cells integrated in the cap and adapted to recharge its power source.

20. The wearable waterproof audio system according to claim 1 wherein one or more control button (s) comprise one or more of the following elements: dome switches, variable resistors, micro switches, micro joystick switches, and/or scroll wheel buttons .

21. The wearable waterproof audio system according to claim 1 wherein one or more of the control button (s) are embedded in the crown portion of the cap.

22. The wearable waterproof audio system according to claim 1 further comprising display means embedded in the cap.

23. A wearable waterproof audio system embedded in a cap comprising a visor, a crown, and a thin audio player means electrically linked to a thin rechargeable power source, said audio player means comprising processing means and memory means, wherein said audio player means, said rechargeable power source, and electric wires connecting them are covered with an isolating layer and attached to a reinforcing stiffening member provided in said visor, and wherein said audio player means further comprises electrical connecting means for earphones and for transferring digital data and charge the power source, and wherein said cap comprises a pouch provided in its crown for holding earphones and said connecting means .

24. A wearable waterproof audio system embedded in a cap comprising a visor, a crown, and a thin audio player means electrically linked to a thin rechargeable power source, said audio player means comprising processing means and memory means, wherein said audio player means, said rechargeable power source, and electric wires connecting them are covered with an isolating layer and attached to a reinforcing stiffening member provided in said visor, and wherein said audio player means further comprises standard earphone and USB connectors electrically linked to the audio player means, and wherein said standard earphone and USB connectors are embedded in a single integrated connector unit, and wherein said cap comprises a pouch provided in its crown for holding earphones and said integrated connector unit.

25. A method for manufacturing a wearable waterproof audio system embedded in a visor of a cap, the method comprising: providing a reinforcing stiffening member of a visor; applying glue over bottom surface areas wherein components of the audio system are to be placed; providing a PCBA circuitry comprising memory and data processing means, said PCBA circuitry is electrically connected to a rechargeable power source, one or more control button (s), and electrical wires used for connecting it to external data systems and/or electric charger; covering said PCBA circuitry, said rechargeable power source, and the connection of said electrical wires to said PCBA circuitry with one or more isolating layer (s); attaching said PCBA circuitry, rechargeable power source, one or more control button (s) and a section of said electrical wires to said reinforcing stiffening member; optionally applying one or more isolating layers over said PCBA circuitry and rechargeable power source and over portions of the reinforcing stiffening member surrounding said PCBA circuitry and said power source; attaching earphones and USB connectors to said electrical wires; and enclosing said reinforcing stiffening member in a visor of a cap and passing the electrical wires and the connectors attached to them through the crown of the cap towards its rear side .

26. A method according to claim 25 further comprising providing a pouch in the crown of the cap.

27. A method according to claim 26 further wherein the earphones and USB connectors are situated in the pouch.

28. A method according to claim 25 wherein the earphones and USB connectors are integrated into a single connector unit.

29. The wearable waterproof audio system according to claim 20 wherein the control button (s) are made using dome switches and flexible printed circuit assemblies coated by one or more isolating layers.

30. The wearable waterproof audio system according to claim 29 wherein the one or more layers comprise an adhesive tape layer and one or more isolating layers applied over ^' it using a liquid coating material.