Patent Publication Number: US-2022212583-A1

Title: Headrest

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is entitled to claim the benefit of, and claims priority to, U.S. provisional patent application Ser. No. 63/134,224 filed Jan. 6, 2021, the entire disclosure of which is incorporated herein by reference. 
    
    
     FIELD 
     The presently disclosed subject matter relates to a headrest for a seat, and more particularly to a headrest for a vehicle seat. 
     BACKGROUND 
     Vehicles, including passenger-type vehicles, include seats for occupants. The seats often have headrests for both passenger comfort and safety. Prior art headrest designs can be complex structures with complex connection mechanisms to the seat. The complexity of the prior art designs contributes to several disadvantages, including at least their high cost and weight. 
     In view of the disadvantages associated with the prior art designs, it would be advantageous to have a headrest that was lightweight, as well as simple in its design so it was easy and cost effective to manufacture. It would also be advantageous for the new headrest to be at least as comfortable and safe, if not more, than the prior art designs. 
     SUMMARY 
     In concordance and agreement with the present invention, a headrest for a vehicle that is lightweight and simple in its design yet easy and cost effective to manufacture while at least as comfortable and safe, if not more, than the prior art designs, has surprisingly been discovered. 
     In one embodiment, a headrest for a vehicle, comprises: at least one component configured to support a head of an occupant, wherein the at least one component is formed of an expanded polypropylene material; and a covering wrapped around at least a portion of the at least one component, wherein an attachment of the covering to the at least one component is hidden from view. 
     As aspects of certain embodiments, the at least one component includes a core having a front portion, a rear portion, an upper portion, a lower portion, and a pair of side portions. 
     As aspects of certain embodiments, the front portion further includes a concave region formed therein. 
     As aspects of certain embodiments, the headrest further comprises a cushioning member disposed on the front portion of the at least one component. 
     As aspects of certain embodiments, the rear portion includes a plurality of facets formed therein. 
     As aspects of certain embodiments, the rear portion includes a pair of first facets, a pair of second facets, and a third facet, wherein each of the second facets connected to a respective one of the first facets, and wherein the third facet is connected to the second facets. 
     As aspects of certain embodiments, the covering is formed of at least of a fabric material, a leather material, a man-made material, and a natural material. 
     As aspects of certain embodiments, the headrest further comprises another covering disposed on a remaining portion of the at least one component. 
     As aspects of certain embodiments, the headrest further comprises a guide structure disposed in the at least one component for coupled to a seat back assembly of the vehicle. 
     In another embodiment, a headrest for a vehicle, comprises: a first component configured to support a head of an occupant; and a second component configured to cooperate with the first component, wherein at least one of the first component and the second component is formed of an expanded polypropylene material. 
     As aspects of certain embodiments, at least one of the first component and the second component includes a core having a front portion, a rear portion, an upper portion, a lower portion, and a pair of side portions. 
     As aspects of certain embodiments, the front portion of the first component further includes a concave region formed therein. 
     As aspects of certain embodiments, the headrest further comprises a cushioning member disposed on the front portion of the first component. 
     As aspects of certain embodiments, the rear portion of the first component includes a plurality of facets formed therein. 
     As aspects of certain embodiments, a front portion of the second component includes a plurality of facets formed therein. 
     As aspects of certain embodiments, the headrest further comprises a covering wrapped around at least a portion of the first component, wherein an attachment of the covering to the first component is hidden from view by a portion of the second component. 
     As aspects of certain embodiments, the headrest further comprises another covering disposed on a portion of the second component. 
     As aspects of certain embodiments, wherein the covering disposed on the portion of the second component is at least one of a coating and a film. 
     As aspects of certain embodiments, the headrest further comprises a guide structure disposed in at least one of the first component and the second component, wherein the guide structure is configured to couple the headrest to a seat back assembly of the vehicle. 
     In yet another embodiment, a headrest for a vehicle, comprises: a first component includes a first core having a first portion and an opposite second portion, wherein the first portion includes a concave region, and wherein a covering is applied over at least the concave region; and a second component includes a second core having a first portion and an opposite second portion, wherein the first portion of the second component is configured to at least partially interface with the second portion of the first component, wherein the second portion of the second component has a coating disposed thereon, and wherein at least one of the first component and the second component is formed from an expanded polypropylene material. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above, as well as other advantages, will become readily apparent to those skilled in the art from the following detailed description when considered in the light of the accompanying drawings in which: 
         FIG. 1  is a rear, perspective view of a headrest  12  according to an embodiment of the presently disclosed subject matter, wherein a covering has been removed; 
         FIG. 2  is a rear, perspective view of the headrest  12  of  FIG. 1 , showing a section of the headrest  12  taken along A-A in  FIG. 1 ; 
         FIG. 3  a partially exploded perspective view of the headrest  12  of 
         FIGS. 1 and 2 ; 
         FIG. 4  is a cross-sectional view of the headrest  12  of  FIGS. 1-3 ; and 
         FIG. 5  is a cross-sectional view of the headrest  12  of  FIGS. 1-3 . 
     
    
    
     DETAILED DESCRIPTION 
     It is to be understood that the device may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments. Hence, specific dimensions, directions or other physical characteristics relating to the embodiments disclosed are not to be considered as limiting, unless the expressly stated otherwise. 
     Turning now to  FIGS. 1-5 , a vehicle seat  10  having a headrest  12  according to an embodiment of the presently disclosed subject matter is depicted. Although  FIGS. 1-5 , and the following description, illustrate and discuss the headrest  12  being configured for the vehicle seat  10 , it should be appreciated that the headrest  12  may be employed in other seating applications, if desired. The vehicle seat  10  may further include a seat back assembly  14  configured to be coupled to the headrest  12  and a seat base assembly (not shown) configured to be coupled to the seat back assembly  14 . 
     In certain embodiments, the headrest  12  may comprise a multi-piece construction. It is within the scope of the present disclosure, however, to make essentially the same headrest  12  in a one-piece, integrally formed and unitary construction. In some embodiments, the headrest  12  may be entirely or substantially symmetrical about an axis, such as an axis that extends from a front to a rear of the headrest  12 . In other words, the headrest  12  may have side-to-side symmetry, but perhaps not, front to back symmetry. 
     As shown in  FIGS. 1-5 , the headrest  12  may comprise a first component  20  and at least a second component  22 . It should be appreciated that the headrest  12  may comprise more or less components than shown. In one embodiment, the components  20 ,  22  may be located together and joined at an intersection  24 . In other embodiments, the components  20 ,  22  may be at least partially nested or stacked. 
     The first component  20  may be located on a front side of the headrest  12 , while the second component  22  may be located on a rear side of the headrest  12 . The terms front and rear are used as a general orientations associated with a front side of the vehicle seat  10  in which a passenger or passengers might be located or seated, while the rear side may be the opposite from the front. 
     In certain embodiments, at least one of the first component  20  and the second component  22  may be constructed at least partially of a foamed material including, but not limited to, an expanded polypropylene material. In one embodiment, the first component  20  and the second component  22  may be substantially entirely formed from expanded polypropylene material. Using the polypropylene material entirely or substantially for at least one of the first and second components  20 ,  22  may be advantageous for many reasons. Among those reasons is that headrest  12  is very lightweight, which may assist in reducing vehicle weight and increasing vehicle fuel economy. The polypropylene material is also readily available, inexpensive, and easy to work with, thus manufacturing costs can be reduced compared with the prior art designs. Further, the polypropylene material may also function as a cushioning material that protects the occupant in the seat as well as other occupants in the vehicle. By way of one example, the polypropylene material may deform or even break upon impacts of a certain degree. Such deformation or breakage of the polypropylene material during impact may function as an energy absorber, such as when the head of the occupant comes into contact with the headrest  12  during a collision, crash or other impact. Thus, the headrest  12  may provide some protection to the occupant&#39;s head during a deceleration of the vehicle that is dangerously too rapid. 
     The headrest  12  also may protect other occupants in the vehicle in a similar manner. For instance, if an occupant in the vehicle is located behind a seat with the headrest  12  described and depicted herein, the headrest  12 , wherein the second component  22  is also constructed of polypropylene, provides the same advantageous protections to a rear occupant should they come into contact with the headrest  12 . Thus, other occupants in the vehicle, in addition to the occupant in the seat with the headrest  12 , are also protected. 
     As more clearly shown in  FIG. 4 , the first component  20  may include a first core  25  having a front portion  26 , a rear portion  27 , an upper portion  28 , a lower portion  29 , and opposing first and second side portions  30 ,  32 . In certain embodiments, the front and rear portions  26 ,  27  may be generally parallel to one another. The upper and lower portions  28 ,  29  may be generally parallel to one another. The side portions  30 ,  32  may also be generally parallel one another. Each of the side portions  30 ,  32  may extend from the front portion  26  to the rear portion  28  and from the upper portion  28  to the lower portion  29 . It is understood that each of the side portions  30 ,  32  may have the same length, height, and angle relative to the front portion  26 , as desired. 
     In certain embodiments, a surface of the front portion  26  of the first core  25  may be generally planar. In a preferable embodiment, the front portion  26  may include a generally concave region  34 . The concave region  34  may contribute to a general cradling effect for a head of an occupant, which leads to increased comfort for the occupant by centering and holding the head. It is understood that the concave region  34  may laterally extend along an entire or partial length of the front portion  26 . It is further understood that the concave region  34  may also transversely extend along an entire or partial height of the front portion  26 . It is appreciated that the front portion  26  may include other features to enhance the comfort for the occupant, if desired. 
     An additional cushion material  36 , such as a foam material, may be located at least partially over the surface of the front portion  26  of the headrest  12 . Preferably, the cushion material  36  is located entirely over the concave region  34  of the front portion  26 . The cushion material  36  may further enhance the comfort for the occupant. 
     It is also permissible for the front portion  26  to be provided with a lamination  37 . The lamination  37  may be in addition to the cushion material  36 . In certain embodiments, the lamination  37  may be a substrate for attachment of other components and features of the headrest  12 . In a non-limiting example, the lamination  37  may be a substrate for a covering  38  of the headrest  12  described hereinafter. It is understood that the lamination  37  may be any suitable material as desired. Further, the lamination  37  may be the same as or in addition to the covering  38 . 
     The trim or covering  38  may be located at least partially over the forward portion  26  of the first component  20 . The covering  38  may also extend at least over the side portions  30 ,  32  of the first component  20 . As more clearly shown in  FIG. 3 , the covering  38  includes a plurality of flaps  41  which may be wrapped around, or otherwise attached, to the rear portion  28  of the first component  20  to secure the covering  38  thereto. In certain embodiments, the covering  38  is secured to the first component  20  by at least one attachment element  39 . As a non-limiting example, the at least one attachment element  39  may be an anchor-type fastener that connects with the covering  38  and extends or otherwise attaches to the first component  20 . In certain embodiments, the at least one attachment element  39  is directly coupled to the covering  38  such as by a sewing process, for example. Various other types of attachment elements  39  may be employed to secure the covering  38  to the first component  20  as desired. In the embodiment shown in  FIGS. 1-5 , the at least one attachment element  39  may be connected to the rear portion  28 , and more preferably disposed adjacent the upper and lower portions  28 ,  29  and the side portions  30 ,  32  of the first component  20  so it is hidden from view in a final assembled headrest  12 . The covering  38  may be constructed of fabric, leather and/or other man-made or natural materials. 
     Locating the covering  38  over just the first component  20  has the advantage of being easier to apply than having to apply the covering  38  to the entire headrest  12 . More particularly, the covering  38  can be wrapped about the first component  20  as described above and, as best seen in FIG. 3 , whereas the prior art coverings had to be pulled down over an entire headrest, which resulted in wrinkles, and areas of the prior art coverings that were not fully supported underneath by the headrest, which gave the prior art coverings an ill-fitting appearance. Connection points of the prior art coverings to the headrest were also more difficult to hide. 
     In some embodiments, the rear portion  28  may comprise a single surface, but in other embodiments the rear portion  28  may comprise multiple surfaces and be multi-faceted. In some embodiments, the rear portion  28  may include one or more deep recessed inlets for air circulation or cooling. In still yet additional embodiments, the rear portion  28  may have sculpted in, or otherwise created or formed, features  43  for hand grips and finger areas if the occupant wanted to grab and adjust the headrest  12 . 
     In the embodiment depicted in  FIGS. 1-5 , the rear portion  28  includes a multi-faceted surface. In a non-limiting example, the rear portion  28  may include first facets  40 , second facets  42 , and a third facet  44 . As shown, each of the first facets  40  extends inwardly from a respective one of the side portions  30 ,  32  and extends generally parallel to the front portion  26 . The first facets  40  may be of equal lengths and extend generally parallel to one another. It is understood, however, that each of the first facets  40  may have any length and extend at any angle relative to one another as desired. 
     The second facets  42 , each directly connected to a respective one of the first facets  40 , may extend rearwardly. As such, the second facets  42  may extend generally transverse the first facets  40 . The second facets  42  may be of equal lengths and extend generally parallel to one another. In certain embodiments, the second facets  42  may have a length greater than a length of the first facets  40 . It is understood that each of the second facets  42  may have any length and extend at any angle relative to one another as desired. 
     The third facet  44 , directly connected to both of the second facets  42 , may form a rearmost surface of the rear portion  28  of the first core  25 . The third facet  44  may extend generally parallel to the forward portion  26 , but it may have a length shorter than the length of the forward portion  26 . In some embodiments, the third facet  44  may have a length shorter than the length of the forward portion  26  by at least the combined lengths of the first facets  40 . The third facet  44  may extend generally transverse to the second facets  42 . It is understood that the third facet  44  may have any length and extend at any angle relative to the first and second facets  40 ,  42 , respectively. The third facet  44  may be generally planar. In some embodiments, however, the third facet  44  may also have additional surfaces. One embodiment of the third facet  44  having additional surfaces is depicted in  FIG. 3 . In such embodiment shown in  FIG. 3 , the third facet  44  may have an upper region  46  and a lower region  48 . The lower region  48  may extend rearwardly, such as at an angle, to a greater extent than the upper region  46 . Each of the facets  40 ,  42 ,  44  may be connected to one another by angled transitions. In some embodiments, the angled transitions may be such as radiused inner and outer corners. 
     Referring now to  FIG. 4 , the second component  22  include a second core  50  having a front portion  52 , a rear portion  53 , an upper portion  54 , a lower portion  55 , and opposing first and second side portions  56 ,  58 . The front portion  52  of the second component  22  may have a complementary shape, size, and configuration to the rear portion  27  of the first component  20 . In the example where the front portion  52  is complementary to the rear portion  53  of the first component  20 , the front portion  52  may be multi-faceted to match the multi-faceted surface of the rear portion  27  of the first component  20  to facilitate a stacking or nesting of the components  20 ,  22  together. Thus, in certain embodiments, the front portion  52  of the second component  22  may have first facets  60  that extend inwardly from the side portions  56 ,  58 . The first facets  60  of the second component  22  may extend generally parallel, and may even contact, when assembled, the first facets  40  of the first component  20 . The first facets  60  may extend generally transverse the side portions  56 ,  58 . Further, the front portion  52  of the second component  22  may also have second facets  62 , directly connected to the first facets  60 , that extend generally rearwardly, and generally transverse the first facets  60 . The second facets  62  of the second component  22  may extend generally parallel, and may even contact, when assembled, the second facets  62  of the first component  20 . Further yet, the front portion  52  may also have a third facet  64  that transitions from the second facets  62  and extends generally transverse the second facets  62 . Similar to the third facet  44  of the first component  20 , the third facet  64  of the second component  22  may be generally planar or it may also have additional surfaces. 
     In certain embodiments, the second facets  62  define a thickness that is approximately equal to a length of the side portions  30 ,  32  of the first component  20 , particularly where the second facets  62  thicken at the lower portion  55 . As illustrated, the second facets  62  and the third facet  64  extend inwardly so that the facets  62 ,  64  comprise just a portion of the width and height of the front portion  52 . Each of the facets  60 ,  62 ,  64  of the second component  22  may be connected to one another by angled transitions. In some embodiments, the angled transitions may be such as radiused inner and outer corners. 
     As shown in  FIG. 5 , the lower portion  55  may extend generally rearwardly to a greater extent than the upper portion  54 . The upper and lower portions  54 ,  55  of the second component  22  may have a complementary shape, size, and configuration to the upper and lower portions  28 ,  29  of the first component  20 . From the above, it can be appreciated that the rear portion  27  of the first component  20  and the front portion  52  of the second component  22  are complementary to one another in terms of size, shape, and configuration. As such, the two components  20 ,  22  may be stacked or nested entirely or partially with one another. This may provide the headrest  12  with a one-piece appearance. 
     The rear portion  53  of the second component  22  may generally follow the front portion  52 . In some cases, a covering  68  may be applied to at least a portion of the rear and side portions  53 ,  56 ,  58 , respectively, of the second component  22 . As more clearly shown in  FIGS. 1-5 , the covering  68  may be applied in a continuous fashion entirely across the rear and side portions  53 ,  56 ,  58 , respectively, of the second component  22 . The covering  68  may be such as a coating or a molded thin plastic film, or it may be a wrapped fabric material, or a natural and/or man-made product. In some embodiments, the covering  68  may be scratch and mar resistant. The covering  68  may also be finished in any color, gloss or texture to harmonize with an interior of the vehicle. When the covering  68  is applied a high-quality appearance is achieved. 
     In certain embodiments, the headrest  12  may include a guide structure  78  configured to facilitate a movement of the headrest  12  relative to the vehicle seat. It should be appreciated that the guide structure  78  may have any shape, size, and configuration as desired. In a non-limiting example depicted in  FIG. 2 , the guide structure  78  may be a generally U-shaped structure including a pair of spaced-apart posts  80  interconnected by a cross-member  82 . The guide structure  78 , and more particularly the posts  80 , may be configured to cooperate with similarly shaped receptacles  84  disposed in the seat back assembly  14  of the seat  10 . In one embodiment, the posts  80  may be located generally adjacent an intersection of the second and third facets  42 ,  44 , respectively. Thus, in some embodiments, the posts  80  may be located inboard from the side portions  30 ,  32  and the at least one attachment element  39  for the covering  38 . 
     At least one of the posts  80  and the cross-member  82  may be configured such as tubes (hollow) or rods (solid) and constructed of a robust material, such as a metal material, a plastic material, and a composite material, for example. At least a portion of the guide structure  78  may further include a coating (e.g. a zinc plating) deposited thereon to enhance an interaction with the components  20 ,  22 . In certain embodiments, each of the posts  80  and the ross-member  82  may be directly embedded into at least one of the cores  25 ,  50  of the first and second components  20 ,  22 , respectively. According, in some embodiments, no additional hardware is needed to secure or mount the guide structure  78  within the headrest  12 . In another embodiment, the guide structure  78  may be formed integrally with the at least one of the first and second components  20 ,  22  and as such fixed in place. This advantageously saves weight, and reduces manufacturing complexity, both of which result in cost savings. 
     In accordance with the provisions of the patent statutes, the present device has been described in what is considered to represent its preferred embodiments. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope.