Patent Publication Number: US-2018041827-A1

Title: Headphone housing assembly

Description:
FIELD OF THE INVENTION 
     The present invention relates generally to headphones and, more particularly, to a headphone housing assembly into which speakers may be easily inserted and removed. 
     BACKGROUND OF THE INVENTION 
     Headphones are popularly used to listen to music on the go. A wide variety of headphones are on the market, and they allow a user to listen to an audio source privately without broadcasting it to others. Typically, headphones are made up of two earpieces that fit over a user&#39;s ears, connected by a headband that holds the headphones in place. The earpieces are typically padded, and fitted with speakers and a transducer. The speakers are connected by speaker wire, which is generally built into the headband. The headband, speakers, and wires are typically built as one fixed piece. Most headphones connect to an audio source such as a smartphone with a cable inserted into an audio jack. Other headphones communicate with the audio source wirelessly via Bluetooth® technology. 
     Ear buds are another device for privately listening to an audio source. Ear buds fit into a user&#39;s ears, and are held in place in the ear rather than with a headband. However, headphones are known to be superior to ear buds in terms of audio quality and comfort. 
     It is desirable to listen to music while engaging in active pursuits, which may necessitate wearing a hat, helmet, or other headgear. This can be problematic in conjunction with headphones because of the bulky nature of traditional headphones. Most hats and helmets will not fit properly on top of headphones. To solve this problem, there are products that provide speakers built into a hat or helmet. But, a good set of speakers can be costly. Thus, it is preferable to have one set of speakers that can be used with a variety of headgear. 
     To that end, products are available that provide modular speakers that can be inserted into hats, helmets, loudspeakers, and so forth. For instance, U.S. Pat. No. 9,925,806 to Krissman et al. is herein incorporated by reference. The headphone assembly of the &#39;806 patent includes two earpieces coupled by a flexible connecting wire, and is mountable within separate headwear such as protective helmets, ski caps, earmuffs, headbands, and so forth. 
     Another shortfall of the headphones currently available is that the speakers cannot be replaced easily. Generally, replacing the speakers in a set of headphones requires hiring a professional. This often makes it more cost-effective to buy a whole new set of headphones, which is wasteful. A user may seek to replace the speakers in their headphones if they degrade, if speaker technology improves, or if the user wishes to upgrade to more powerful speakers. 
     The present invention solves these needs and others, by providing a headphone housing assembly that removably houses a pair of speakers. The headphone assembly snaps open and closed, allowing speakers and wiring to be inserted or removed with ease. 
     SUMMARY OF THE INVENTION 
     Briefly, and in general terms, by example and not limitation, the invention provides a headphone assembly for receiving a removable earpiece assembly (i.e., removable speakers). The headphone assembly is suited to receive a removable earpiece assembly comprising two earpieces connected by a flexible wire (i.e., speaker wire). The headphone assembly comprises a headband assembly and two substantially annular ear cups disposed at the ends of the headband assembly. The headband assembly is sized to extend over the head of a user, and comprises an inner headband and an outer headband, which fit together in a removable manner so that the wire of the earpiece assembly can be inserted and removed into the headband assembly. Each ear cup has an annular opening configured to hold an earpiece in a removable manner. Thus, the earpiece assembly can be inserted or removed into the headphone assembly so that the earpieces are housed in the ear cups and the wire is enclosed within the headband assembly. 
     In a detailed aspect of an exemplary embodiment in accordance with the invention, the headband assembly comprises an outer headband, an inner headband, and a frame. The inner and outer headbands are removable to allow speaker wire to be threaded through the frame. 
     In another detailed aspect of an exemplary embodiment in accordance with the invention, a hinge assembly is provided to clip the ear cups to the headband assembly. The hinge assembly clips open to allow the headband pieces to be disassembled. When the headband assembly is reassembled, the hinge assembly clips shut, holding the headphone assembly together in one piece. 
     More specifically, in an exemplary embodiment in accordance with the invention, the headband further comprises a head pad and ear pads attached to the inner surface of each ear cup. The pads are made of a soft material for a comfortable fit. 
     In another detailed aspect of an exemplary embodiment in accordance with the invention, the interior wall of each of the ear cups is composed of a plurality of planar segments, defining a polygonal opening. The polygonal opening is sized and shaped so that a speaker fits in the center of each ear cup in a snap-fit arrangement. The ear cups are fitted with teeth that hold the speakers in place, and attachment members to facilitate attachment of the ear cups to the headband assembly. 
     It is accordingly an object of the present invention to provide a headphone assembly that removably houses a removable earpiece assembly. 
     For purposes of summarizing the invention and the advantages achieved over the prior art, certain advantages of the invention have been described herein. Of course, it is to be understood that not necessarily all such advantages may be achieved in accordance with any particular embodiment of the invention. Thus, for example, those skilled in the art will recognize that the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein. 
     All of these embodiments are intended to be within the scope of the invention herein disclosed. These and other embodiments of the present invention will become readily apparent to those skilled in the art from the following detailed description of the preferred embodiments having reference to the attached figures, the invention not being limited to any particular preferred embodiment disclosed. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Embodiments of the present invention will now be described, by way of example only, with reference to the following drawings in which: 
         FIG. 1  is a perspective view of a headphone housing assembly in accordance with the present invention. 
         FIG. 2  is a top perspective view of the headphone assembly of  FIG. 1 . 
         FIG. 3  is a front perspective view of the headphone assembly of  FIG. 1 . 
         FIG. 4  is a side perspective view of the headphone assembly of  FIG. 1 . 
         FIG. 5  is exploded view of the headphone assembly of  FIG. 1 . 
         FIG. 6  is a front exploded view of the headphone assembly of  FIG. 1 . 
         FIG. 7  is a side exploded view of the headphone assembly of  FIG. 1 . 
         FIG. 8A  is front perspective view of an ear cup of the present invention, depicting the inner surface of the ear cup with a speaker partially inserted therein. 
         FIG. 8B  is front perspective view of an ear cup of the present invention, depicting the inner surface of the ear cup with a speaker fully inserted therein. 
         FIG. 9  is a side view of the headphone assembly of  FIG. 1 , with the outer headband removed, depicting a speaker wire running from the speaker into the frame. 
         FIG. 10  is a view of a removable earpiece assembly, which the headphone assembly of  FIGS. 1-9  is configured to receive. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     With reference now to the drawings, and particularly  FIGS. 1-4 , there is shown a headphone assembly  10  for receiving a removable earpiece assembly comprising a headband assembly  20 , ear cups  30 , and a hinge assembly  40  for connecting the two. 
       FIG. 10  shows an exemplary removable earpiece assembly  50 , which the present invention is configured to receive. The removable earpiece assembly has a first earpiece  52 , a second earpiece  54 , and a flexible wire  56  connecting the two. In a preferred embodiment, the earpieces  52 ,  54  have perimeters defined by a plurality of planar segments  58 . Preferably, each earpiece contains a Bluetooth®-enabled speaker in wireless communication with a device for playing audio. The earpieces may also be speakers that communicate with a device with a cable connection. 
     Referring now to  FIGS. 5-7 , the headband assembly  20  comprises an outer headband  21 , an inner headband  22 , and a frame  24 . The inner headband  22  provides a plurality of clips  28  to removably attach the inner headband  22  to the frame  24 . As shown in  FIG. 5 , the frame  24  comprises two thin bands of material terminating in an attachment means at each end, by means of which it may be attached to the ear cups  30  via the hinge assembly  40 . The frame  24  is preferably composed of metal, such as steel. The inner headband  22  and clips  28  are preferably formed from a single piece of plastic, such as polyethylene. 
     Other configurations are also possible, but the key aspect of the headband assembly  20  is that it can accommodate the insertion of speaker wire, keeping it out of the way. For example, in another embodiment, the headband assembly includes an inner headband and an outer headband which fit together to house the wire without the need for a frame. The headband could also be a single piece configured to hold a flexible wire in place. In any case, when the invention is used, as preferred, with two Bluetooth®-enabled speakers connected by a flexible wire, the invention provides headphones with no loose wiring, which is ideal for the active user. 
     The outer headband  21  is flexible, so as to be removably attachable over the inner headband  22  and frame  24 . The outer headband  21  is preferably made of silicone, which is flexible and durable. The pliable nature of silicone allows the outer headband to easily be fitted onto the inner headband and frame. The outer headband may, however, be made of any material desired, such as plastic or metal. The headband assembly may further provide a head pad  26  for a more comfortable fit. The head pad  26  is composed of ethylene-vinyl acetate (EVA), or similar material. 
       FIGS. 8A-9  show the headphone assembly  10  with speakers inserted therein. The ear cups  30  are substantially annular in shape, each forming an opening sized to accommodate an earpiece  52 ,  54 . The ear cups  30  further provide teeth  35  to hold the earpieces  52 ,  54  in place, an attachment member  37  to facilitate clipping the ear cups  30  to the hinge assembly  40  and headband assembly  20 , and a channel  36  through which to feed speaker wire  56 . The teeth  35  are disposed proximate to the interior wall  33  of the outer surface  32  of the ear cups  30 , and permit speakers  53 ,  54  to be secured in the openings of the ear cups in a snap fit. The ear cups  30 , teeth  35 , attachment member  37 , and channel  36  are preferably composed of a single piece of plastic such as ABS. Referring now to  FIGS. 5-7 , each ear cup  30  is fitted with an ear pad  38  for comfort, which may be composed of polyurethane or similar material. 
     Each ear cup  30  includes an interior wall  33  forming the opening and having teeth  35  disposed thereabout. In the exemplary embodiment, the interior wall  33  comprises a plurality of planar segments  39  (shown in  FIG. 1 ), which forms a polygonal opening. The outer wall  34  of each ear cup also includes a plurality of planar segments  39 , which in the exemplary embodiment forms a polygonal shape. The ear cups  30  are preferably fitted with a plurality of teeth  35  to accommodate the insertion of an earpiece  52 ,  54 . 
     Referring now to  FIGS. 5-7 , the hinge assembly  40  comprises an ear cup hinge  42 , a hinge bracket  44 , and a frame cover  46 . The frame cover  46  is attached to the end of the frame  24 . The ear cup hinge  42  clips open and shut. When the ear cup hinge  42  is in an open position, the inner headband  22  and outer headband  21  may be detached from the ear cups  30 . Once the inner and outer headbands  21 ,  22  are reattached, such as after the insertion of earpieces  52 ,  54 , the ear cup hinge  42  clips down, holding the headphone assembly  10  together. 
     To insert a removable earpiece assembly  50  into the headphone housing assembly  10 , a user unclips the hinge assembly  40 , then removes the outer headband  21  and inner headband  22  from the frame  24 . As shown in  FIG. 8A , an earpiece  52 ,  54  is first inserted into the inner surface  31  of an ear cup so that it is transverse to the body of the ear cup  30 . The earpiece  52 ,  54  so fits through the ear cup  30  when inserted directly above the channel  36 . The user then pulls the earpiece  52 ,  54  through the ear cup  30 , so that it extends from the outer surface of the ear cup  32 . As shown in  FIG. 8B , the user then rotates the earpiece  52 ,  54  so that it is parallel to the body of the ear cup  30 , and which point the earpiece  52 ,  54  clicks in to fit securely in the ear cup  30 , held snug by the teeth  35 . 
     The headphone housing assembly  10  is suited to accommodate two speakers  52 ,  54  connected by a speaker wire  56 , such as CHIPS®—Universal Bluetooth Wireless Helmet Audio, manufactured by Outdoor Tech. 
     Referring now to  FIG. 9 , the wire  56  is guided to exit the ear cup  30  through channel  36 . The wire  56  is then fed between the two bands comprising the frame  24 . When the same process is applied to both earpieces  52 ,  54 , the wire  56  will connect them while lying substantially parallel to the frame  24 . 
     Next, the inner headband  22  is clipped on to the frame  24  with the clips  28 . The outer headband  21  is then slipped over the inner headband  22 , frame  24 , and wire  56 . Finally, the ear cup hinges  42  snap down, securing the headband assembly  20  together. 
     To remove the earpiece assembly  50 , the process is accomplished in reverse—the hinge assemblies  40  are snapped open, and the outer headband  21  and inner headband  22  are detached from the frame  24 . The earpieces  52 ,  54  may then be removed from the ear cups  30 . 
     Although the invention has been disclosed in detail with reference only to the exemplary embodiments, those skilled in the art will appreciate that various other embodiments can be provided without departing from the scope of the invention. Accordingly, the invention is defined only by the claims set forth below.