Patent Publication Number: US-9854348-B2

Title: Flexible conformal cushioned headphones

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application is based upon and claims priority to U.S. Provisional Application No. 62/390,616 filed Apr. 4, 2016 and hereby incorporated by reference herein. 
    
    
     FIELD OF THE INVENTION 
     This invention relates to headphones for converting electrical signals to sounds. 
     BACKGROUND 
     Headphones used to convert electrical signals into sounds find widespread use, for example, for private listening to music, news and the like. When used in conjunction with a microphone headphones permit two way communication, for example, using cellular telephones. 
     Headphones are intended to be worn on the head of the user and for them to be truly “hands free” must reliably maintain their position. Comfort is also a factor, especially if headphones are to be worn for extended periods. Furthermore, the headphones should be adjustable to securely fit a wide range of head sizes and shapes as well as a wide variety of wearing styles. For example, many individuals use headphones to induce sleep, and thus it is important for headphones to be comfortable and maintain their position on the head of the wearer when the wearer is lying down with their head on a pillow. The design choices found in prior art headphones are a compromise which favor some requirements, for example, characteristics that help the headphones maintain their position, over other requirements, such as comfort and adjustability. There is clearly a need for headphones having characteristics which strike a more balanced design for the considerations of adjustability and comfort. 
     SUMMARY 
     The invention concerns headphones. In one example embodiment the headphones comprise an elongate, flexible, deformable armature. An elastic strip is attached lengthwise along the armature. At least a first speaker is supported by the armature. In a specific example embodiment the armature comprises a deformable metal core. By way of further example a sheath surrounds the armature. The sheath comprises a flexible substrate. The substrate may comprise a fabric. A layer of resilient, flexible material may be positioned between the sheath and the armature. By way of example the resilient, flexible material comprises polymer foam. 
     In an example embodiment the first speaker comprises a wireless receiver and a power source. A further example embodiment comprises a second speaker supported by the armature. Another example embodiment comprises an electrical connector. First and second electrical conductors connect the first and second speakers to the electrical connector. 
     In a particular example embodiment the armature has first and second ends oppositely disposed. The first speaker is supported by the armature at the first end thereof and the second speaker is supported at the second end thereof. By way of further example the armature forms respective first and second loops at the first and second ends. In an example embodiment, first and second pockets are formed in the sheath. The first and second pockets are respectively positioned adjacent to the first and second ends of the armature. The first speaker is received in the first pocket, the second speaker is received in the second pocket in this embodiment. 
     The invention further encompasses headphones for supporting a speaker comprising, by way of example, an elongate, flexible, deformable armature. An elastic strip is attached lengthwise along the armature. A flexible sheath surrounds the armature. A specific example embodiment further comprises a layer of resilient, flexible material positioned between the sheath and the armature. In an example embodiment, a first speaker is supported by the armature. By way of example the first speaker is supported between a layer of resilient flexible material and the sheath. Another example embodiment comprises a second speaker supported by the armature. The first speaker is positioned at a first end of the armature; the second speaker is positioned at a second end of the armature in this example. By way of further example the armature forms respective first and second loops at respective first and second ends of the armature. Another embodiment comprises first and second pockets formed in the sheath. The first and second pockets are respectively positioned adjacent to respective first and second ends of the armature in an example embodiment. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a plan view of an example embodiment of headphones according to the invention; 
         FIG. 2  is a cross sectional plan view of the headphones shown in  FIG. 1 ; 
         FIG. 3  is a cross sectional view taken at line  3 - 3  of  FIG. 1 ; and 
         FIG. 4  is a cross sectional view taken at line  4 - 4  of  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION 
       FIGS. 1 and 2  show an example embodiment of a set of flexible, conformal, cushioned headphones  10  according to the invention. As shown in cross section in  FIG. 2 , headphones  10  comprise an elongate, flexible, deformable armature  12 . An example armature  12 , as shown in  FIG. 3 , comprises a deformable metal core  14  surrounded by a flexible sleeve  16 . In a practical example the metal core  14  may comprise one or more copper wires  18 , and the sleeve  16  may comprise a polymer insulating layer. Copper is advantageous because it readily deforms plastically without failing and can be deformed many times to adapt the headphones to a desired shape. As shown in  FIG. 2 , an elastic strip  20  is attached lengthwise along the armature  12 . Elastic strip  20  may comprise woven elastic yarns attached, either continuously to or at a plurality of points  21 , along the length of the armature  12 . Elastic strip  20  applies a compression force to the armature  12  to bias it into a curved configuration. The armature  12  remains flexible however, and can deform to conform comfortably to the shape a wearer&#39;s head, the elastic strip  20  providing the biasing force so that the headphones remain securely in place on the wearer&#39;s head. The elastic strip  20  may be attached to the armature  12  by stitching, cinching, heat fusing, and adhesives to cite a few examples. U-shaped elastic anchors  21  are attached between armature  12  and a flexible sheath  22  which surrounds the armature. The U-shaped anchors are also formed of an elastic strip and provide guidance determining how the headphones  10  conform to the ears of a wearer. 
     As shown in  FIGS. 1-3 , flexible sheath  22  surrounds the armature  12  and its elastic strip  20 . Sheath  22  comprises a flexible substrate, for example, a fabric such as felt, or woven or knitted fabrics of cotton, wool or polyester, as well as blends of synthetic and natural fibers. It is advantageous that the sheath  22  be formed of a material which is comfortable to wear against the skin. The fabric forming the sheath  22  may be stitched together, as shown at  23 , to form a desired shape as shown in  FIG. 1 . Openings  25  may be located at various positions in the sheath  22  to provide access to the interior of the headphones  10 . The openings in this example embodiment comprise flaps secured in a closed position by hook and loop fasteners and permit insertion and adjustment of internal components, such as speakers and wires described below. 
     As shown in  FIGS. 2 and 4 , a layer of resilient, flexible material  24  is positioned between the sheath  22  and the armature  12 . Material  24  serves a cushioning function and is advantageously formed of a polymer foam. Material  24  may extend along the entire length of armature  12  as shown in  FIGS. 2 and 3  or be confined to regions at the first and second ends  26  and  28  of the armature  12  as shown in  FIG. 4  (first end  26  shown). 
     As shown in  FIG. 2 , armature  12  supports first and second speakers  30  and  32 . In one example embodiment, speakers  30  and  32  further comprise electrical conductors  34 ,  36 , (wires) which connect the speakers  30  and  32  to an electrical connector  38 , such as a plug engageable with a standard audio jack.  FIG. 4  shows a wireless embodiment, wherein the speakers  30  and  32  ( 30  shown) comprise a radio frequency receiver  40  and a power source powering the speakers, such as a battery  42 . It is anticipated that this embodiment will allow compatibility with Bluetooth wireless technology standards. 
     As shown in  FIG. 2 , speakers  30  and  32  are supported by the armature  12  at its opposite ends  26  and  28 . To enhance the support function the ends  26  and  28  of armature  12  may be formed into respective first and second loops  44  and  46 . The flexible, resilient layer  24  surrounds the loops  44  and  46  to provide cushioning to the wearer when lying down on the headphones  10 . To ensure that the speakers  30  and  32  remain at fixed positions within the sheath  22  so that they can be reliably located adjacent to a wearer&#39;s ears, the speakers are received within respective first and second pockets  48  and  50 . As shown in  FIG. 4 , pockets  48  and  50  ( 48  shown) are formed in sheath  22  adjacent to respective loops  44  and  46 . To maximize audio transmission the speakers  30  and  32  are positioned between the layer of flexible resilient material  24  and the sheath  22 . Hook and loop fasteners may be used to secure pockets  48  and  50  closed, as well as to provide a secure closure to seams in the sheath  22  which, when open, provide access to the interior of the headphones for the placement of speakers or other components. 
     It is expected that headphones such as example embodiment  10  according to the invention will provide improved comfort to the wearers while still maintaining position securely on the wearer&#39;s head even when in contact with pillows or other surfaces.