Abstract:
A method for preparing a wire for installation in a headrest entertainment system includes forming a receiving portion in a headrest, inserting a first wire having first connectors through a headrest post and into the receiving portion, mounting a media device to the headrest, the media device comprising a second wire having second connectors, connecting the first connectors and the second connectors, folding the connected first wire and the second wire, placing the folded wires inside a connector cover, and inserting the connector cover into the receiving portion.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This application is a Continuation-in-Part of U.S. application Ser. No. 11/593,306, filed on Nov. 6, 2006, the disclosure of which is incorporated herein in its entirety by reference, 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Technical Field 
         [0003]    The present disclosure relates to methods and devices for preparing wires, and more particularly to methods and devices for preparing wires for installation in a headrest entertainment system for a vehicle. 
         [0004]    2. Discussion of Related Art 
         [0005]    An entertainment system for a vehicle, such as a headrest entertainment system, is popular because passengers can enjoy audio and video entertainment on the road. The headrest entertainment system includes, for example a media unit with a display, and a media player. The media player can be formed in the media unit or other parts of the vehicle. 
         [0006]    The media unit can be electrically connected to a media player in another headrest, for example, a DVD player, via connectors attached to, for example, a wire harness and/or a distribution box. The connectors are formed at the end of a wire(s), which run from the media unit. The connectors are also formed at the end of a wire(s), which run from the wire harness and/or the distribution box. The wire(s) including connectors can be fed up headrest supports into the headrest. The connectors from the media unit and the connectors from the wire harness are connected and placed in the headrest. However, the connector/wire harness combination occupies large space in the headrest. 
         [0007]    Thus, a need exists for a wire organizing method for reducing the amount of space occupied by the connector/wire harness combination in the headrest. 
       SUMMARY OF THE INVENTION 
       [0008]    According to an embodiment of the present invention, a method for preparing a wire for installation in a headrest entertainment system includes forming a receiving portion in a headrest, inserting a first wire having first connectors through a headrest post and into the receiving portion, mounting a media device to the headrest, the media device comprising a second wire having second connectors connecting the first connectors and the second connectors, folding the connected first wire and the second wire, placing the folded wires inside a connector cover, and inserting the connector cover into the receiving portion. 
         [0009]    The method may further comprise wrapping the first connectors attached to the first wire with a wire wrapper for covering the first connectors, feeding the first wire through the headrest post, and removing the wire wrapper. 
         [0010]    Placing the folded wires inside the connector cover may comprise opening the connector cover, and closing the connector cover around the folded wires. 
         [0011]    The receiving portion may receive the headrest post. 
         [0012]    The receiving portion can be formed near a bottom of the headrest. 
         [0013]    Two receiving portions can be formed near bottom corners of the headrest. 
         [0014]    The connector cover can be formed in a tube shape. 
         [0015]    The tube-shaped connector cover may comprise a cavity. 
         [0016]    The connectors may comprise electrical components for providing at least one of power, ground and audio/video connections for the entertainment system. 
         [0017]    According to an embodiment of the present invention, a headrest entertainment system for a vehicle comprises a headrest including a receiving portion, a first wire having first connectors, a media device disposed in the headrest, and including a second wire having second connectors, and a connector cover for receiving mated first and second wires, wherein the connector cover is disposed in the receiving portion. 
         [0018]    The connector cover may comprise a cavity formed therein. 
         [0019]    The connector cover may be formed in a tube shape. 
         [0020]    Two receiving portions can be formed near bottom corners of the headrest. 
         [0021]    According to an embodiment of the present invention, a device for preparing a wire for installation in a headrest entertainment system for a vehicle comprises a connector cover for receiving the wire including a plurality of connectors in a cavity formed in the connector cover. 
         [0022]    The connector cover may be formed in a tube shape. 
         [0023]    The connector cover may comprise at least an opening through which the wire is inserted into the cavity. 
         [0024]    The tube-shaped connector cover can be opened into two pieces to receive the wire in the cavity. 
         [0025]    The connector cover may comprise plastic. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0026]    Exemplary embodiments of the present invention can be understood in more detail from the following descriptions taken in conjunction with the accompanying drawings, of which: 
           [0027]      FIG. 1  shows a headrest entertainment system with shrink-wrapped wire connectors, according to an embodiment of the present invention; 
           [0028]      FIG. 2  shows a close-up view of the shrink-wrapped connectors of  FIG. 1 ; 
           [0029]      FIG. 3  shows a top view of a headrest entertainment system with a media unit pivoted outward with respect to a headrest, according to an embodiment of the present invention; 
           [0030]      FIG. 4  shows a view of wire connectors wrapped in braided sleeving, according to an embodiment of the present invention; 
           [0031]      FIG. 5A  shows a front view of a headrest including a wired connection, according to an embodiment of the present invention; 
           [0032]      FIG. 5B  shows a close-up view of the wired connection shown in  FIG. 5A , according to an embodiment of the present invention; 
           [0033]      FIGS. 6A-6B  show an electrical connector running from a media unit, according to an embodiment of the present invention; 
           [0034]      FIG. 6C  shows a connector positioned in the media unit for receiving the electrical connector shown in  FIG. 6D , according to an embodiment of the present invention; 
           [0035]      FIG. 6D  shows an electrical connector, according to an embodiment of the present invention; 
           [0036]      FIG. 7  shows a front view of a headrest including a first receiving portion and a second receiving portion according to an embodiment of the present invention; 
           [0037]      FIG. 8  shows a wire inserted into a first receiving portion according to an embodiment of the present invention; 
           [0038]      FIG. 9  shows a front view of a headrest and a media unit attached to the headrest according to an embodiment of the present invention; 
           [0039]      FIG. 10  shows wires and connectors routed out of a headrest according to an embodiment of the present invention; 
           [0040]      FIG. 11  shows connectors mated each other according to an embodiment of the present invention; 
           [0041]      FIG. 12   a  shows connectors and wires folded and inserted into a connector cover according to an embodiment of the present invention; 
           [0042]      FIG. 12   b  shows a front view of a connector cover according to an embodiment of the present invention; 
           [0043]      FIG. 13  shows wires and connectors placed in a connector cover according to an embodiment of the present invention; 
           [0044]      FIG. 14  shows a connector cover placed in a receiving portion of a headrest according to an embodiment of the present invention; 
           [0045]      FIG. 15  shows a bottom view of a headrest according to an embodiment of the present invention; 
           [0046]      FIG. 16  shows a cross-sectional view of a headrest taken along the line I-I′ of  FIG. 15  according to an embodiment of the present invention; and 
           [0047]      FIG. 17  shows a headrest harness according to an exemplary embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS 
       [0048]    Exemplary embodiments of the present invention will now be described more fully hereinafter below in more detail with reference to the accompanying drawings. This invention may, however, be embodied in different forms and should not be construed as limited to the embodiments set forth herein. 
         [0049]    Referring to  FIG. 1 , a headrest  10  includes an entertainment system  100  mounted therein. The entertainment system  100  includes a media unit  120  with a display  130  having a screen for displaying a video program. The screen is preferably an LCD type display, but may be another type of display, such as, for example, an organic LED or electro-luminescent display. The video program is supplied from a media player, for example, a DVD player  140  provided behind the display  130  (see  FIG. 3 ). The media source may also be, for example, a CD-ROM player, a video game player, a videocassette player, a television tuner, a radio tuner, a wireless receiver, an MP3 player, a digital video recorder, and/or a device for playing media supplied from a portable storage device (ergo, a portable hard drive, memory cards, flash memory sticks, key drives, thumb drives). Alternatively, the display  130  can be electrically connected to an auxiliary media source through auxiliary port  142 . 
         [0050]    In another alternative, the display is electrically connected to a media player, for example, another DVD player in another headrest, via one of the connectors  150  attached to, for example, a wire harness, a power supply, and/or a distribution box (not shown). The connectors  150  are formed at the end of a wire(s)  125 , which run from the entertainment system  100 . For example, the wire  125  may include a plurality of wires, and each connector  150  can be attached to each of the plurality of wires. The wire(s)  125 , including connectors  150  are fed through the headrest supports  15  and the connectors  150  are connected to, for example, the wire harness. The connectors  150  preferably include electrical connectors, for example, pin connectors, for connecting to the wire harness. The connectors  150  provide, for example, power, ground, and audio/video inputs and outputs to and from the entertainment system  100 . For example, video from DVD player  140  may be supplied to a display located in another headrest of the vehicle. The connectors  150  also include control lines for a wireless modulator for supplying wireless audio to a vehicle sound system or for communication of the video, audio or control signals between the media player and display  130 . 
         [0051]    Referring to  FIGS. 1 and 2 , in order to facilitate feeding of the wires  125  including the connectors  150  from an upper portion of the headrest  10  through the headrest posts  15 , the connectors  150  are shrink wrapped in, for example, heat shrink tubing  160 . The heat shrink tubing  160  is such that it provides a compact and low profile covering for the connectors  150  by conforming to the size and shape of the connectors  150 . The heat shrink tubing  160  preferably includes partially polymerized plastic. The heat shrink tubing  160  may be formed from material, such as, for example, polyolefin and fluoropolymer resins, such as, fluorinated ethylene propylene (FEP) and perfluoroalkoxy (PFA). 
         [0052]    Once passed through the headrest posts  15 , and fed to the wire harness, a user/installer of the headrest entertainment system can remove the tubing  160  by, for example, cutting off the tubing  160 , thereby exposing the connectors  150  so that the connectors  150  can be mated with, for example, the harness. 
         [0053]    In an embodiment of the present invention, the wires  125  including the connectors  150  can be fed up the headrest posts  15  into the headrest  10 . In order to facilitate feeding of the wires  125  including the connectors  150  from the headrest posts  15  through the headrest  10 , the connectors  150  are shrink wrapped in, for example, heat shrink tubing  160  or braided sleeving  170 . Once passed through the headrest posts  15 , and fed to the wire harness, a user/installer of the headrest entertainment system can remove the tubing  160  by, for example, cutting off the tubing  160 , thereby exposing the connectors  150  so that the connectors  150  can be mated with, for example, the harness. 
         [0054]    In an embodiment, the connectors  150  mated with the harness can be folded or bent, for example, in half for reducing the amount of space occupied by the connector/harness combination and placed inside a connector cover (not shown). The connector cover, enclosing the connectors  150  mated with the harness, can be placed inside the headrest  10 . Detail descriptions are illustrated in connection with  FIGS. 7-16 . 
         [0055]    Referring to  FIG. 4 , as an alternative to the heat shrink tubing  160 , braided sleeving  170  can be used to wrap the connectors  150 . The braided sleeving  170  may be formed from, for example, polyethylene terepthalate (PET), fiberglass, and/or polyester. In an embodiment, a stiff wire  172  is attached to wire  125  at a location near the end of the braided sleeving  170 . The stiff wire further facilitates feeding of the wire  125  through the headrest posts  15  and through a seat to which the headrest  10  is mounted. The stiff wire  172  provides a rigid member which can be gripped, by, for example, a wire puller, to enable smooth feeding of the wire  125  through the headrest post  15  to the bottom of a seat. The stiff wire  172  may comprise metal, such as, for example, aluminum, spring steel or plastic. In another alternative, the stiff wire  172  may also be attached at the end of the heat shrink tubing  160 . 
         [0056]    As shown in  FIG. 4 , tape  173 , for example, electrical tape, is wrapped around the wire  125  at the ends of the braided sleeving  170  to protect the connectors  150  and to hold the stiff wire  172  in place. As an alternative to the tape  173 , heat shrink tubing may be used. 
         [0057]    At the bottom of a seat, when the connectors  150  are to be mounted to a wire harness, the tape  173  (or heat shrink tubing) is removed by a user/installer by, for example, cutting the tape  173  (or heat shrink tubing). Then, the braided sleeving  170  is removed by carefully pulling on the wire  125  and holding the braided sleeving  170 . The braided sleeving  170  may be expanded by pushing around the end of the braided sleeving  170  where the tape  173  (or heat shrink tubing) was removed. 
         [0058]    Referring to  FIGS. 6A-6D , the wired connection running from the media unit  120  preferably includes a two-headed electrical connector  180 , including, for example, pin connectors  181  and  182 . The pin connector  181  connects to a mating pin connector  183  positioned in the headrest  10  (see  FIGS. 5A-5 ), which is, in turn, connected to wire  125  running through the headrest support rods  15  to connect to a wire harness (not shown). By unplugging the pin connectors  181 ,  183  from each other, a user is able to remove the media unit  120  from the headrest  10  without cutting or pulling apart the wires. The pin connector  182  connects to a mating pin connector  184  positioned in the media unit  120 . The electrical connector  180  is positioned at a rear portion of the media unit  120 , with pin connector  182  connected to pin connector  184 . 
         [0059]      FIG. 7  shows a front view of a headrest including a first receiving portion and a second receiving portion according to an embodiment of the present invention. Referring to  FIG. 7 , the headrest  10  includes a first receiving portion A and a second receiving portion B. The media unit  120  is disposed in the second receiving portion B. The second receiving portion B is recessed to receive the media unit, for example, pivotally attached thereto. In an embodiment, two first receiving portions A can be formed, for example, at the bottom corners of the headrest  10 . The first receiving portion A and the second receiving portion B can be connected to each other so that a wire from the media unit  120  can be routed out of the headrest  10  via the first receiving portion A. The headrest supports  15  are inserted into the first receiving portion A and are attached to a transverse supporting bar  16  such that the headrest  10  can be securely attached to the headrest supports  15 . 
         [0060]      FIG. 8  shows wires inserted into first receiving portions according to an embodiment of the present invention. Referring to  FIG. 8 , the wires  125  including the connectors  150  are fed up the headrest posts  15  into the first receiving portions A of the headrest  10 . To facilitate an efficient feeding, the connectors  150  can be wrapped with, for example, the wire wrapper  170  for covering the connectors  150 . The wires  125  are fed through the headrest posts  15 . The wires  125  are routed out of the headrest  10  through the first receiving portions A. Then, the wire wrapper  170  can be removed. 
         [0061]      FIG. 9  shows a front view of a headrest and a media unit attached to the headrest according to an embodiment of the present invention. Referring to  FIG. 9 , the media unit  120  is pivoted away from the second receiving portion B of the headrest  10 . The media unit  120  includes wires  225  carrying, for example, power, audio and video signals, and having a plurality of connectors  250  to be mated with connectors  150  of the wires  125 . The connectors  150 ,  250  comprise electrical components for providing at least one of power, ground and audio/video connections for the entertainment system. The wires  225  are routed from the media unit  120  and out of the headrest  10  through the first receiving portion A to connect with the wires  125  having connectors  150 . 
         [0062]      FIG. 10  shows wires and connectors routed out of a headrest according to an embodiment of the present invention.  FIG. 11  shows connectors mated with each other according to an embodiment of the present invention. 
         [0063]    Referring to  FIGS. 10 and 11 , the connectors  150  and  250  are mated. Since the mated connectors  150 ,  250  and harnesses are loosely organized, the connector/harness combination may occupy large space inside the headrest  10 . The loosely organized harnesses can be short circuited when contacted with another harness in the headrest  10 . 
         [0064]      FIG. 12   a  shows connectors and wires folded and inserted into a connector cover according to an embodiment of the present invention.  FIG. 12   b  shows a front view of a connector cover according to an embodiment of the present invention. 
         [0065]    Referring to  FIGS. 12   a  and  12   b,  the wire harness having the mated connectors  150 ,  250  can be folded or bent, for example, in half, for reducing the amount of space occupied by the connector/harness combination and placed inside the connector cover  300 . In an embodiment, the plurality of wires from each of the wires  125 ,  225  can be folded inside the connector cover  300  and the connector cover  300  can be snapped closed around the wires  125 ,  225 . In an embodiment, the plurality of wires  125 ,  225  can be folded outside the connector cover  300  and then inserted into the connector cover  300  through an opening C. The opening C can be formed at one or both sides of the connector cover  300 . 
         [0066]    The connector cover  300 , enclosing the mated connectors  150 ,  250  and the harness, can be placed inside the headrest  10 . The connector cover  300  comprises a cavity  315  to receive the mated connectors  150 ,  250  and the wire harness. In an embodiment, the connector cover  300  comprises the opening C for guiding the wire harness into the cavity  315 . In an embodiment, the connector cover  300  can be formed in, for example, a tube shape. The tube-shape connector cover  300  can be opened into two pieces as shown in  FIG. 12   a  and receives the wire harness inside the cavity  315 . The connector cover  300  can comprise, for example plastic. 
         [0067]      FIG. 13  shows wires inserted into a connector cover according to an embodiment of the present invention. Referring to  FIG. 13 , once the wire harness having mated connectors  150 ,  250  are folded, for example, in half, in the connector cover  300 , the connector cover  300  is closed using, for example, a mating switch  333 . The connector cover  300  can be opened to disconnect the connectors  150 ,  250  when a different media unit is used. 
         [0068]      FIG. 14  shows a connector cover inserted into a receiving portion of a headrest according to an embodiment of the present invention.  FIG. 15  shows a bottom view of a headrest according to an embodiment of the present invention.  FIG. 16  shows a cross-sectional view of a headrest taken along the line I-I′ of  FIG. 15  according to an embodiment of the present invention. 
         [0069]    The connector cover  300  (see  FIGS. 12 and 13 ) enclosing connectors and harnesses can be placed in the first receiving portion A. The receiving portion A may have a size enough to enclose the connector cover  300 . 
         [0070]    Referring to  FIGS. 14-16 , the connector covers  300  are inserted in the first receiving portions A after the connector covers  300  are closed. Each connector cover  300  can be inserted into the first receiving portions A disposed at bottom corners of the headrest  10 . In an embodiment, the connector covers  300  can be disposed near the headrest supports  15 . 
         [0071]      FIG. 17  shows a headrest harness according to an exemplary embodiment of the present invention. The headrest harness  1000  includes a first cable  1125   a,  a second cable  1125   b,  and a connecting pin housing  1135 . The first cable  1125   a  and the second cable  1125   b  can be tied using, for example, a shrink sleeving  1145  at one end of each of the cables  1125   a,    1125   b.  A plurality of wires  1150  in the first and the second cables  1125   a,    1125   b  are received by the connecting pin housing  1135 . The first cable  1125   a  includes a Deutsches Institut für Normung (DIN) connector  1127   a,  and the second cable  1125   b  includes a DIN connector  1127   b  at the opposite end of the connecting pin housing  1135 . The first and second cables  1125   a,    1125   b  include strain relievers  1129   a,    1129   b,  respectively. 
         [0072]    According to an exemplary embodiment of the present invention, the strain reliever  1129   a  can have different areas so that the strain reliever  1129   a  can fit into different sized hollow portions of the headrest post  15  and prevent the cable  1125   a  from being pulled down the headrest post  15 . 
         [0073]    According to an exemplary embodiment of the present invention, the plurality of wires  1150  at each end of cables  1125   a,    1125   b  can be enclosed by a first and second wrapping part  1121   a,    1121   b.  Each wrapping part may comprise, for exam pie, plastic or rubber. The first and second wrapping part  1121   a,    1121   b  may have different colors. For example, the first wrapping part  1121   a  has a blue color and the second wrapping part  1121   b  has a yellow color. The first wrapping part  1121   a  having a blue color can be mated with a connector having a blue color. The second wrapping part  1121   b  having a yellow color can be mated with a connector having a yellow color. Accordingly, plugging a cable into a wrong connector can be prevented. The first wrapping part  1121   a,  the second wrapping part  1121   b  and the DIN connectors  1127   a,    1127   b  can be sized small enough to fit through the headrest post  15 . 
         [0074]    Although exemplary embodiments have been described herein with reference to the accompanying drawings, it is to be understood that the present invention is not limited to these precise embodiments but various changes and modifications can be made by one skilled in the art without departing from the spirit and scope of the present invention. All such changes and modifications are intended to be included within the scope of the invention as defined by the appended claims.