Article and method for wire embedded headwear

Abstract

A deformable article of headwear constructed from a yarn impregnated with a malleable wire. The impregnated yarn is comprised of a headwear material comprised of a natural or synthetic fiber used for making headwear, including straw, cotton, or a composite material. Optionally, lacquer may be applied to the article to improve its ability to retain shape, however, the article would maintain its shape even after degradation of the lacquer dues to the impregnated yarn.

What is claimed: 
     
         1 . A method of manufacturing a wire embedded headwear article, comprising the steps of:
 (a) Impregnating yarn or a yarn-like material with a malleable wire therein; and   (b) Weaving an article of headwear using said impregnated yarn or yarn-like material.   
     
     
         2 . The method of  claim 1  further comprising the step of applying lacquer to the article of headwear. 
     
     
         3 . The method of  claim 1 , wherein said impregnated yarn or yarn-like material is used to weave a fabric, which is then used to form the article of headwear. 
     
     
         4 . The method of  claim 1 , wherein the yarn or yarn-like material is impregnated with a malleable wire by wrapping headwear material around the malleable wire at angle so that the entire length of the wire is covered. 
     
     
         5 . The method of  claim 1 , wherein the yarn or yarn-like material is formed by either dipping or spraying the malleable wire into a liquefied headwear material, or passing the malleable wire under a cascade of liquefied headwear material. 
     
     
         6 . The method of  claim 1 , wherein the yarn or yarn-like material is formed by inserting the malleable wire into the yarn or yarn-like material. 
     
     
         7 . A wire embedded headwear article utilizing the method of  claim 1 , comprising yarn or yarn-like material having a continuously malleable wire embedded therein. 
     
     
         8 . The embedded headwear article of  claim 7 , wherein the yarn or yarn-like material is made from a headwear material that is wrapped around the entire length of the malleable wire. 
     
     
         9 . The embedded headwear article of  claim 7 , wherein the yarn or yarn-like material is made from a malleable wire that is coated with liquefied headwear material. 
     
     
         10 . The embedded headwear article of  claim 7 , wherein the malleable wire is inserted into the yarn or yarn-like material.