Abstract:
A headrest insert for an automobile headrest has first and second rod holders for engaging support rods of the headrest. A web interconnects the first and second rod holders and includes a corrugated section accommodating twisting or skewing of the rod holders relative to one another. The insert can be formed as a monolithic body of plastic.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     The present regular United States patent application claims the benefits of U.S. Provisional Application Ser. No. 60/707,880 filed on Aug. 12, 2005. 
     
    
     FIELD OF THE INVENTION  
       [0002]     The present invention relates to automobile headrests, and, more particularly, the invention pertains to headrest inserts for headrest assemblies commonly found in automobiles.  
       BACKGROUND OF THE INVENTION  
       [0003]     Seats in automobiles and other vehicles are designed to protect the occupant from injury during accidents and other occurrences. As part of the seat design, it is known to extend portions of the seat back to a height that provides support behind the head and neck of the seat occupant. Posterior support of the head and neck can reduce whiplash and other injuries that are common in moving accidents, and even it stationary accidents occurring with only minimal violence. While some seat backs are of a continuous form from the seat bottom to an elevation at or above an occupants head, it is also known to provide the headrest as a vertically adjustable and removable attachment to the seat back.  
         [0004]     In a known design for automobile seats, the seat back has two sleeves having openings at the top of the seat back. A headrest includes corresponding rods, tubes or other elongated bodies that can be inserted into the sleeves. By providing two sleeves in the seat back and two appropriate rods at opposite ends of the headrest, sound structural support is provided. It is known to provide the headrest as a generally curved body from one end thereof to the opposite end thereof so that the posterior head of the occupant is comfortably received against the headrest.  
         [0005]     The headrest includes a substructure between the elongated rods generally forming the curved shape of the headrest. Padding and an outer covering are provided over the substructure. However, the substructure must provide sufficient rigidity and support between the opposed elongated rods so that the occupants head is adequately supported even in a violent crash.  
         [0006]     Difficulties can be encountered with known headrest subassemblies or inserts. For adequate support, the elongated rods of the headrest extend a significant distance into the seat back. The space between the rods is relatively short, the rods are narrow and the sleeves are only sufficiently wide to receive the rods. Accordingly, with the rods relatively long and interconnected at only one end, relative skewing of one rod compared to the other can occur, Skewing or racking can make it difficult to operate or adjust the headrest relative to the seat body. The relatively rigid headrest inserts have not accommodated skewing of the support rods, one relative to the other.  
         [0007]     Further, the sleeves in the seat backs are rigidly secured between frame members of the seat. Again, since the headrest support rods are relatively long and narrow, any slight misalignment or inaccurate positioning of the sleeves relative to each other can result in binding against the support rods, and difficult operation if the sleeves are not perfectly parallel and properly aligned axially with the openings at the top of the seat back. Even a slight variation in parallelism between the two sleeves coupled with a very slight deviation from parallelism between the headrest support rods can result in difficult operation of the headrest.  
         [0008]     U.S. Pat. No. 6,224,158 and U.S. Pat. No. 6,789,850 disclose headrest inserts having transitions at the centers thereof.  
         [0009]     There is a need in the industry for a more easily operated headrest and one that more readily accommodates normal day-to-day uses and common conditions for headrests.  
       SUMMARY OF THE INVENTION  
       [0010]     The present invention provides a headrest insert that accommodates skewing or misalignment of the headrest support rods relative to sleeves in the seat back.  
         [0011]     In one aspect thereof, the present invention provides a headrest insert for an automobiles headrest, with first and second rod holders and a web connected to and spanning the area between the first and second rod holders. The web has a top edge and a bottom edge. A flex portion in the web accommodates relative angular movement between the first rod holder and the second rod holder.  
         [0012]     In another aspect thereof, the present invention provides a headrest insert with first and second rod holder adapted for engaging a support rod inserted therein. A web interconnects the first and second rod holders. At least one corrugated portion in the web has a series of ridges and valleys extending from a top edge of the web to a bottom edge of the web. 
        In a still further aspect thereof, the present invention provides a headrest insert with first and second rod receivers adapted for engaging support rods inserted therein and a web interconnecting the first and second rod holders. The web has a top edge and a bottom edge. At least one region in the web has a compressible and extendable structure disposed from the top edge to the bottom edge, and enabling accordion-like movement of the first and second rod receivers.        
 
         [0014]     An advantage of the present invention is providing a headrest insert that accommodates and compensates for minor skewing of headrest support rods.  
         [0015]     Another advantage of the present invention is providing a headrest insert that facilitates smooth operation of a headrest, without undue effort by the occupant.  
         [0016]     Still another advantage of the present invention is providing a headrest insert that adequately supports the structure in crash events.  
         [0017]     Other features and advantages of the invention will become apparent to those skilled in the art upon review of the following detailed description, claims and drawings in which like numerals are used to designate like features. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0018]      FIG. 1  is a perspective view of a headrest insert in accordance with the present invention;  
         [0019]      FIG. 2  is an elevational view of the headrest insert shown in  FIG. 1 , with support rods installed therein;  
         [0020]      FIG. 3  is a top view of the headrest insert shown in  FIGS. 1 and 2 ;  
         [0021]      FIG. 4  is an end elevational view of the headrest insert shown in the previous drawings; and  
         [0022]      FIG. 5  is a perspective view of another embodiment of the present invention. 
     
    
       [0023]     Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use herein of “including”, “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof, as well as additional items and equivalents thereof.  
       DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0024]     Referring now more specifically to the drawings and to  FIG. 1  in particular, a headrest insert  10  in accordance with the present invention is shown. Insert  10  is coupled with first and second support rods  12 ,  14  ( FIG. 2 ) for attachment to a vehicle seat (not shown). The general shape and configuration of insert  10  is selected to enhance or complement the overall appearance and functionality of the vehicle seat (not shown) on which it is installed. Accordingly, the length, height and general shape can vary from one installation to another installation.  
         [0025]     Headrest insert  10  includes first and second rod holders  16 ,  18  for attachment to support rods  12  and  14 , and a band or web  20  joined to and extending between rod holders  16 ,  18 . Insert  10  can be molded from suitable plastics such as polypropylene; however, other materials also can be used. In the exemplary embodiment shown, insert  10  is molded as a single monolithic body including rod holders  16 ,  18  and band or web  20 .  
         [0026]     Rod holder  16  includes a cylindrical rod receiver  22  open at one end  24  at the bottom of insert  10  and closed at a top end  26 . Support rod  12  is inserted into rod receiver  22  through open end  24  and extends through rod receiver  22  to and against closed top and  26 . Rod receiver  22  defines an internal diameter selected with an outer dimension of support rod  12  such that the support rod is received in rod receiver  22  with a strong interference fit so that relative movement of the support rod and insert  10  is inhibited. Alternatively, bonding with adhesive, welding or other joining techniques can be used to secure the support rod in rod receiver  22 . Rod holder  16  includes a flange  28  extending along the length of rod receiver  22  on opposite sides thereof and across the top of rod receiver  22  at top end  26 . Band  20  merges with flange  28  along a margin  30 .  
         [0027]     Rod holder  18  is structured similarly to rod holder  16  and includes a rod receiver  32  having an open end  34  and a closed top end  36  all similar to the corresponding structures in rod holder  16 . Further, rod holder  18  includes a flange  38  similar to flange  28  which joins with web  20  at a margin  40 . Support rod  14  is inserted into rod receiver  32  through open end  34  and extends through rod receiver  32  to and against closed top and  36 . Rod receiver  32  defines an internal diameter selected with an outer dimension of rod  14  such that the rod is received in rod receiver  22  with a strong interference fit so that relative movement of the rod  14  and insert  10  is inhibited. Alternatively, bonding with adhesive, welding or other joining techniques can be used to secure support rod  14  in rod receiver  32 .  
         [0028]     Web  20  is a generally elongated body including a center plate  50  and flex portions  52 ,  54  at opposite ends of center plate  50 , between plate  50  and rod holders  16 ,  18  respectively. Center plate  50  defines an opening  56  therethrough. Opening  56  in the exemplary embodiment is an elongated opening oriented generally in a horizontal direction; however, other shapes and orientations also can be used. Opening  56  enhances twisting or other movement or slight deformation or distortion of center plate  50  out of its true and unaltered configuration. Accordingly, two or more smaller openings can be used. It is also contemplated that in some embodiments of the present invention an opening or openings  56  in the center of band  20  are not required.  
         [0029]     Flex portion  52 , as perhaps best seen in  FIGS. 1 and 3 , is a corrugated body, which, when viewed from the front illustrated in  FIG. 1 , has adjoining ridges  60  and valleys  62  extending from a top edge  64  of web  20  to a bottom edge  66  of web  20 . As readily understood by those skilled in the art, when viewed from the opposite side from the side shown in  FIG. 1 , the valleys and ridges are reversed. The corrugated or serpentine structure of flex portion  52  inherently allows relative side-to-side and front-to-back twisting of rod holder  16  relative to center band  20 . Flex portion  52  allows slight accordion like movement of rod holder  16  connected thereto, facilitating movement of open end  24  and top end  26  in substantially opposite directions.  
         [0030]     Flex portion  54 , also perhaps best seen in  FIGS. 1 and 3 , is a corrugated body similar to flex portion  52 . Accordingly, when viewed from the front illustrated in  FIG. 1 , flex portion  54  has adjoining ridges  70  and valleys  72  extending from top edge  64  of web  20  to bottom edge  66  of web  20 . As readily understood by those skilled in the art, when viewed from the opposite side from the side shown in  FIG. 1 , the valleys and ridges are reversed. The corrugated or serpentine structure of flex portion  54  inherently allows relative side-to-side and front-to-back twisting of rod holder  18  relative to center band  20 . Flex portion  54  allows slight accordion like movement of rod holder  18  connected thereto, facilitating movement of open end  34  and top end  36  in substantially opposite directions.  
         [0031]     Flex portions  52 ,  54  and opening  56  accommodate twisting of rod holders  16  and  18  relative to one another and to band or web  20  side-to-side, front-to-back and at angular relationships relative to each other and to center band or web  20 . Accordingly, as rods  12 ,  14  are inserted in rod receivers in a seat (not shown) the necessary angular movement of one with respect to the other is accommodated by band or web  20 . Rods  12  and  14  can adjust as necessary to slide smoothly and easily into and out of the seat back as adjustment occurs. However, in spite of any relative twisting that may occur, band  20  remains structurally sound and provides adequate support within a headrest for an occupant of a seat on which the headrest is used. Flex portions  52 ,  54  have a height similar to the height of plate  50 , adding to the overall soundness of insert  10  while enabling necessary distortion to facilitate adjusting the headrest in which the insert is used. In the exemplary embodiment shown in the drawings, flex portions  52 ,  54  are of increasing height relative to center plate  50  nearer rod holders  16 ,  18 . The overall rigidity or flexibility of a flex portions  52 ,  54  can be selected as desired by controlling the choice of materials for insert  10 , the thickness of material in flex portions  52 ,  54  and the size of corrugations formed therein, including the frequency and amplitude of such corrugations.  
         [0032]      FIG. 5  illustrates a second embodiment of the present invention in which headrest insert  80  includes rod holders  86 ,  88  on opposite ends of a band or web  90 . Rod holder  86  includes a cylindrical rod receiver  92  having an open end  94  and an opened, but narrowed top end  96 . Opposed flange portions  98 ,  100  are provided on opposite sides of rod receiver  92 . Rod holder  88  is structured similarly to the structure of rod holder  86 , having a rod receiver  102  with opposed ends  104 ,  106  and flange portions  108  and  110 . Band or web  80  includes a center plate  120  with corrugated flex portions  122 ,  124  on opposite ends thereof. An opening  126  is provided in center plate  120 . Accordingly, center plate  120  and flex portions  122 ,  124  are substantially similar to center plate  50  and flex portions  52 ,  54  described previously herein.  
         [0033]     Headrest insert  80  accommodates twisting and skewing as required, but may have manufacturing advantages for molding when compared with the embodiment shown as headrest insert  10 .  
         [0034]     With support rods  12 ,  14  installed therein, rod holders  16 ,  18  of headrest insert  10  and rod holders  86 ,  88  of headrest insert  80  are substantially rigid along the lengths thereof, from the open bottom ends thereof to the top ends thereof. If the lower distal ends of support rods  12 ,  14  are adjusted from their natural, non-deflected installed positions to align with holding structure or sleeves in a seat (not shown), the top ends and bottom ends of the rod holders are moved in substantially opposite directions. Flex portions  52 ,  54 ,  122 ,  124  are simultaneously compressible and extendable in different areas thereof, thereby distributing stresses caused by the distortion of inserts  10  or  80  and enabling accordion like movement whereby the top ends and bottom ends of the rod holders can move in substantially opposite directions to facilitate movement of support rods  12 ,  14  in the sleeves (not shown) in which the rods are held. With the improved flexibility afforded by flex portions  52 ,  54 ,  122 ,  124 , inserts  10 ,  80  and webs  20 ,  90  thereof can be made of a thicker material or stronger material for improved strength and performance of a headrest in which the insert is used.  
         [0035]     Variations and modifications of the foregoing are within the scope of the present invention. It is understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawings. All of these different combinations constitute various alternative aspects of the present invention. The embodiments described herein explain the best modes known for practicing the invention and will enable others skilled in the art to utilize the invention. The claims are to be construed to include alternative embodiments to the extent permitted by the prior art.  
         [0036]     Various features of the invention are set forth in the following claims.