Abstract:
Described are lightweight headrests with a perimeter frame  200  with an open central region. The open central region is spanned by a suspension membrane  100  held in tension. The suspension membrane provides support and cushioning functions to a passenger head without the need for internal structures or compression cushions. The perimeter frame of the headrest may have additional cross members spanning the rear portion of the headrest. These cross members may provide additional structure or locate attachment points for the headrest onto the seat.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is related to and claims priority benefits from U.S. Provisional Application Ser. No. 62/012,799 (“the &#39;799 application”), filed on Jun. 16, 2014, entitled “Suspension Mesh Headrest”. The &#39;799 application is hereby incorporated in its entirety by this reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The field of the invention relates to passenger seats or the like, and more particularly to lightweight components of passenger seats. 
       BACKGROUND 
       [0003]    There has been continuous movement in carrier industries, particularly with air carriers, to move towards passenger seats that are lighter, simpler, and easier to manufacture and assemble. Lighter seats offer improved fuel economy, and increase available payload for passengers and luggage. The passenger seat is also a major design feature and the structure that passengers are most often in contact with during travel. As such, there is a simultaneous push for more visually appealing designs and passenger comfort. It is desirable to reduce weight in parts or subassemblies of passenger seats to further these goals. 
         [0004]    Traditional passenger seat headrests are manufactured with internal frames that are covered with cushions and outer panels that provide the headrest surface. These headrests can be heavy, bulky, and complex to manufacture. 
         [0005]    In certain cases, it may be desirable to provide a headrest with a membrane stretched in tension over a supporting structure. The membrane may be held in tension and provide the support and cushion to a passenger&#39;s head without the need for a cushion or heavy internal structure. The membrane may be configured to provide differing levels of support and cushion at different locations, providing enhanced comfort to a passenger. A headrest with membrane may support a number of aesthetic features, like colors, logos, or other visually pleasing designs, eliminating the need for outer panels. The combination of structure, support, and outer visual appearance further simplifies and lightens the headrest. 
       SUMMARY 
       [0006]    The terms “invention,” “the invention,” “this invention” and “the present invention” used in this patent are intended to refer broadly to all of the subject matter of this patent and the patent claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below. Embodiments of the invention covered by this patent are defined by the claims below, not this summary. This summary is a high-level overview of various aspects of the invention and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this patent, any or all drawings and each claim. 
         [0007]    According to certain embodiments of the present invention, a suspension headrest may comprise a perimeter frame that may comprise a forward side, an aft side, and an open central region. A suspension membrane may be affixed to the forward side of the perimeter frame. The suspension membrane may be held in tension across the open central region of the perimeter frame and may deflect into the open central region when load is applied to the suspension membrane. 
         [0008]    In some embodiments, the perimeter frame may comprise a rounded rectangle. The perimeter frame may comprise a curve such that the forward side of the perimeter frame is substantially concave and the aft side of the perimeter frame is substantially convex. 
         [0009]    In certain embodiments, the suspension membrane may comprise a mesh. 
         [0010]    In some embodiments, the suspension membrane may comprise a two-way stretch fabric. The suspension membrane may further comprise a four-way stretch fabric. 
         [0011]    In certain embodiments, the tension of the suspension membrane in a first direction may be different from the tension of the suspension membrane in a second direction orthogonal to the first direction. 
         [0012]    In some embodiments, the suspension headrest may further comprise at least one cross member spanning the open central region on the aft side of the perimeter frame, wherein the at least one cross member partially defines an expansion space. The at least one cross member may be convex with respect to the aft side of the perimeter frame. 
         [0013]    In certain embodiments, the at least one cross member may comprise a first cross member and a second cross member. The first cross member may be substantially orthogonal to the second cross member. 
         [0014]    In some embodiments, the perimeter frame may deflect to provide support in response to loading. In further embodiments, the perimeter frame and the at least one cross member may deflect to provide support in response to loading. 
         [0015]    In certain embodiments, the at least one cross member may comprise a horizontal cross member. The horizontal cross member may be vertically offset. 
         [0016]    In some embodiments, the suspension membrane and the perimeter frame may comprise a single molded piece of material of varying thickness. 
         [0017]    In certain embodiments, the suspension membrane may comprise an integrated reinforcement selected from the group consisting of foam, woven thread, and sleeved reinforcements. 
         [0018]    In some embodiments, the suspension headrest may comprise articulating lateral portions. 
         [0019]    In certain embodiments, the suspension headrest may further comprise cushioning material on the at least one cross member. 
         [0020]    According to certain embodiments of the present invention, a suspension headrest may comprise a perimeter frame that may comprise a rounded rectangle comprising an open central region, a forward side, and an aft side. A suspension membrane may comprise a two-way stretch fabric held in tension across the forward side of the perimeter frame and spanning the open central region. A vertical cross member may span the aft side of the perimeter frame. A horizontal cross member may span the aft side of the perimeter frame orthogonal to the vertical cross member. The perimeter frame may comprise a curve such that the forward side of the perimeter frame is substantially concave and the horizontal cross member may comprise a curve to follow the profile of the aft side of the perimeter frame. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0021]      FIG. 1  is a perspective view of a suspension headrest according to certain embodiments of the present invention. 
           [0022]      FIG. 2  is a perspective view of the suspension headrest of  FIG. 1 . 
           [0023]      FIG. 3  is a top plan view of the suspension headrest of  FIG. 1 . 
           [0024]      FIG. 4  is a rear perspective view of the suspension headrest of  FIG. 1 . 
           [0025]      FIG. 5  is a side elevation view of the suspension headrest of  FIG. 1 . 
           [0026]      FIG. 6  is a perspective view of a suspension headrest according to certain embodiments of the present invention. 
           [0027]      FIG. 7  is a perspective view of a suspension headrest mounted to a passenger seat. 
       
    
    
     DETAILED DESCRIPTION 
       [0028]    The subject matter of embodiments of the present invention is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described. 
         [0029]    The described embodiments of the invention provide a lightweight headrest with a suspension membrane and supporting frame for passenger seats. While the headrests are discussed for use with airline passenger seats, they are by no means so limited. Rather, embodiments of the suspension headrest may be used in any passenger seat including, but not limited to, automotive, marine, bus, train, or other commercial passenger seats. 
         [0030]    In some embodiments of the present invention, as shown in  FIGS. 1-5 , a suspension headrest  1  comprises a perimeter frame  200  with a forward side  201 , an aft side  202  and a suspension membrane  100  held in tension across an open central region  203 . The suspension membrane  100  serves to support and cushion the load from a passenger head when it is rested against the suspension headrest  1 . The suspension membrane  100  may be comprised of any number of materials. However, the suspension membrane  100  is preferably comprised of a material that may flex or deflect under load, and that may support tension loads while maintaining flexibility and resisting permanent deformation. In certain embodiments, the suspension membrane  100  may comprise a polymer, elastomer, two-way stretch fabric, four-way stretch fabric, a mesh, netting, or other material that may remain flexible to cushion and support a head while allowing for the support of loads. In some embodiments, the suspension membrane  100  material may be selected based on an engineering or regulatory standard, such as standards for fire resistance requirements for commercial air travel. 
         [0031]    The suspension membrane  100  may be affixed to the perimeter frame  200  in any number of ways as desired or required for a particular application. For example, mechanical fasteners, such as, but not limited to, staples, nails, pins, screws, rivets, or the like may be used to affix the suspension membrane  100  to the perimeter frame  200 . In other embodiments, adhesives such as epoxy, glue, or other bonding agents may be used. The suspension membrane  100  may also be formed or molded as an integral part of the perimeter frame  200 . The suspension membrane  100  may also be attached to the perimeter frame  200  by wrapping the material of the suspension membrane  100  around the perimeter frame  200  and attaching the suspension membrane  100  material to itself. The self-attachment may be achieved through stitching, adhesion, mechanical fastening, or other attachment means. In certain embodiments, the suspension membrane  100  may be attached to the perimeter frame  200  by placing the two parts together and applying heat such that the material of the suspension membrane  100 , perimeter frame  200 , or both melts. The suspension membrane  100  and perimeter frame  200  may then be held together from the solidified melt material. It is also possible, and in some cases desirable, to form or mold the suspension membrane  100  and perimeter frame  200  as a single piece of material. By selectively increasing or decreasing the thickness of the material, a suspension membrane  100  that is flexible may be integrally molded with a relatively stiffer perimeter frame  200  as a single piece while still providing the function of a multiple-part suspension headrest  1 . 
         [0032]    The perimeter frame  200  may be planar, or may have a curved shape such that the forward side  201  of the perimeter frame  200  is generally concave in at least one dimension, and the aft side  202  of the perimeter frame  200  is generally convex in at least one dimension. The perimeter frame  200  may feature additional support or structure from optional vertical cross member  208  and/or horizontal cross member  210  that may be attached to the perimeter frame at attachment points  212 . In some embodiments, the vertical cross member  208  and horizontal cross member  210  may pass over or through one another, and may or may not be attached to one another, at the crossover  213 . 
         [0033]    The suspension membrane  100  can be configured to provide varying degrees of support, deflection, and to tailor these characteristics across the area of the suspension membrane  100  that spans the open central region  203 . For example, the suspension membrane  100  may be affixed or attached to the perimeter frame  200  in such a way that the initial tension in one direction is different than the tension in a different direction. In certain embodiments, the suspension membrane  100  may be configured with a higher degree of initial tension in the vertical direction to give additional support to loads in the fore-aft direction, while having less initial tension in the horizontal direction to provide additional cushion for lateral loads. Initial tension of the suspension membrane  100  may also be influenced by the weave of the suspension membrane  100  in applications where the suspension membrane  100  comprises a fabric or woven material. The weave of the suspension membrane  100  may be tighter in one direction compared to another. Similarly, the suspension membrane  100  may have differing types of threads (i.e., stronger or weaker threads) at selected locations throughout its area to provide varying degrees of cushion. 
         [0034]    The suspension membrane  100  may also include an integrated reinforcement  104  to provide additional support, enhance comfort, and/or provide additional shape to the suspension membrane  100 . In certain embodiments, the suspension membrane  100  may include foam strips, springs, woven in threads, or strips of pre-stressed fabrics as an integrated reinforcement  104  to alter or adapt the amount of cushion or support in the suspension membrane  100  and suspension cushion  1 . In other embodiments, the suspension membrane  100  may have sleeves or apertures included that allow insertion of reinforcements similar to those noted above. 
         [0035]    The perimeter frame  200  may be constructed from a number of different materials including, but not limited to, injection molded plastic, aluminum, stainless steel, fiber reinforced plastics, carbon fiber, composites, polycarbonate, polypropylene, other metallic materials, or other polymers. The selection of perimeter frame  200  material may be made based on the particular environment or requirements of an application, including anticipated forces, cost of material, cost of manufacture, number of units required, and/or regulatory requirements. For example, the material of the perimeter frame  200  (and also of the vertical cross member  208  and/or horizontal cross member  210 ) may be selected for compliance with a safety or fire resistance standard, such as those that are often used for commercial airline applications. 
         [0036]    The perimeter frame  200  serves to provide support to the suspension membrane  100 , and to give shape, structure, and attachment points for the suspension headrest  1 . As a result, the geometry of the perimeter frame  200 , including the use or omission of cross members  208 ,  210  may vary depending upon the requirements of any particular application. For example, in certain embodiments, the perimeter frame  200  may be planar without any curvature. In other embodiments, the perimeter frame  200  may have a curvature such that the forward side  201  is concave and the aft side  202  is convex as shown in  FIGS. 1-5 . The geometry of the perimeter frame  200  may also determine the geometry of the open central region  203  and expansion space  206 , which the suspension membrane  100  moves through and into, respectively. The curvature of the perimeter frame  200  may be used to increase the lateral support of the passenger&#39;s head, or it may be used to increase the volume of the expansion space  206 . For example, the curvature of the perimeter frame  200  may allow for additional deflection of the suspension membrane  100  before it contacts any portions of the perimeter frame  200  or any cross members  208 ,  210 . 
         [0037]    The suspension headrest  1  may also include a vertical cross member  208  and/or a horizontal cross member  210 . These cross members  208 ,  210  may take on any number of configurations and orientations as desired or required for a particular application. For example, the cross members  208 ,  210  may be positioned orthogonally to one another as shown in  FIG. 4 . In certain embodiments, the cross members  208 ,  210  may be positioned in different orientations and at different angles to one another as they span the open central region  203  of the perimeter frame  200 . The cross members  208 ,  210  may also have different curvatures to provide different shapes and support profiles for the suspension headrest  1 . The cross members  208 ,  210  may have curvatures that generally follow those of the perimeter frame  200 , or they may be bowed to a greater or lesser extent than the perimeter frame  200 . Adjustments to the curvature of the cross members  208 ,  210  may also influence the amount of expansion space  206  available in any particular embodiment of the suspension headrest  1 . In certain embodiments, the cross members  208 ,  210  may be located in offset positions. For example, in  FIG. 4 , the horizontal cross member  210  is located above the center of the perimeter frame  200 . Offsetting one or more of the cross members  208 ,  210  may provide for tailored cushioning and support profiles for passengers of different size and weight. For example, raising or lowering the horizontal cross member  210  may provide for altering the support profile of the suspension headrest  1  to accommodate varying positions of the center of gravity of a passenger head. To facilitate further adjustability, the cross members  208 ,  210  may be removably affixed to the perimeter frame  200  at the attachment points  212  or other locations along the perimeter frame  200 . The cross members  208 ,  210  may be attached with mechanical fasteners, adhesives, magnets, or they may snap into notches formed or molded into the perimeter frame  200 . Similarly, the crossover  213  may feature attachment means between the cross members  208 ,  210  as with the connection of the cross members  208 ,  210  to the perimeter frame  200 . In certain embodiments, the cross members  208 ,  210  may be formed or molded as a single piece. In other embodiments, the cross members  208 ,  210  will not be affixed to one another at the crossover  213 , and will independently provide support to the perimeter frame  200 . 
         [0038]    During use, the perimeter frame  200  and optional cross members  208 ,  210  may provide a part of the flexibility and cushioning action of the suspension headrest  1 . The perimeter frame  200  and cross members  208 ,  210  may be formed of materials or given geometries that allow them to deflect and function as springs. In certain embodiments, the load of the passenger&#39;s head will be absorbed by the suspension membrane  100 , the perimeter frame  200 , and/or the cross members  208 ,  210  deflecting and supporting loads as group. 
         [0039]    The cross members  208 ,  210  may be lined with a cushioning material, such as, but not limited to, foam or another compressible material. The foam (not shown) would allow for cushioning of the passenger&#39;s head in an emergency maneuver, accident, or any other situation where the force of the passenger head on the suspension membrane  100  is great enough that the suspension membrane  100  may deflect to an extent that contact between the passenger head and cross members  208 ,  210  may occur. 
         [0040]    Still referring to  FIGS. 1-5 , the suspension headrest  1  may support and cushion the head and neck of a passenger through the deflection of the suspension membrane  100  through the open central region  203  of the perimeter frame  200 . When a passenger head is placed upon or rested against the suspension headrest  1 , the suspension membrane  100 , which is held in an initial state of tension because it is stretched across the perimeter frame  200 , will deflect from its initial position in an aft direction generally through the open central region  203  of the perimeter frame  200  and into the expansion space  206 . As the suspension membrane  100  is displaced, the level of tension in the suspension membrane  100  will increase from its initial state, and take up the load of the passenger&#39;s head. In certain embodiments, the suspension membrane  100  may take up all of the load of the passenger&#39;s head during normal use without the passenger head contacting the perimeter frame  200 , or the optional vertical cross member  208  and/or optional horizontal cross member  210 . However, in some embodiments, perimeter frame  200 , vertical cross member  208 , and/or horizontal cross member  210  may be used assist the suspension membrane  100  and partially support the passenger&#39;s head. Furthermore, in certain situations with higher than normal loads, such as during a crash, emergency maneuver, or other incident, the suspension membrane  100  may deflect to a degree that the passenger&#39;s head may contact the perimeter frame  200 , vertical cross member  208 , and/or horizontal cross member  210 . In these circumstances, the perimeter frame  200 , vertical cross member  208 , and/or horizontal cross member  210  may be lined with a cushioning material, such as rubber, foam, or another compressible material, to enhance passenger comfort and safety. 
         [0041]      FIG. 6  is a perspective view of a suspension headrest  1  comprising a perimeter frame  200  with a suspension membrane  100  affixed to the forward side  201  of the perimeter frame  200 . The suspension membrane  100  spans an open central region  203  of the perimeter frame  200  in tension. The suspension headrest  1  also includes a vertical cross member  208  and a horizontal cross member  210 , which are attached to the aft side  202  of the perimeter frame  200  at attachment points  212 . In certain embodiments, the vertical cross member  208  and the horizontal cross member  210  may overlap, pass over, or pass through one another at crossover  213 . At crossover  213 , the vertical cross member  208  and the horizontal cross member  210  may be affixed to one another, or they may not be attached to one another. In certain embodiments, a mount  218  may be affixed at the crossover  213  or alone the vertical cross member  208  or the horizontal cross member  210 . The mount  218  allows the suspension headrest  1  to be attached or affixed to a passenger seat (not shown). The mount  218  can be either a fixed mount, or a pivoting, rotating, or sliding mount that allows for adjusting the position and angle of the suspension headrest  1 . In certain embodiments, the mount  218  allows the suspension headrest  1  to maintain the same level of movement as a traditional headrest. 
         [0042]      FIG. 7  is a perspective view of a suspension headrest  1  mounted on a passenger seat  2 . The suspension headrest  1  comprises a suspension membrane  100 . In certain embodiments, as shown in  FIG. 7 , the suspension membrane  100  may be a mesh, mesh-like, or perforated material. Suspension membrane  100  materials that are perforated, mesh, or otherwise allow for air circulation through the suspension membrane  100  and around the passenger head may reduce heat buildup and perspiration, enhancing passenger comfort. 
         [0043]    The suspension headrest  1  may be provided as a retrofit to replace traditional headrests, or it may be included as an integral part to a passenger seat  2 . A suspension headrest  1  may offer increased opportunities for customization and decoration to the passenger seat  2 . For example, the space inside a suspension headrest  1  that is normally occupied by a cushion may be utilized for integrating speakers or other entertainment devices. The suspension membrane  100 , which may be easily replaceable in certain embodiments, may be decorated or styled to contain logos, advertising, or aesthetically pleasing designs and colors. In certain embodiments, the suspension membrane  100  may comprise a mesh material that could have a two-tone or changing appearance by weaving different color threads into the material. In further embodiments, the suspension headrest  1  may not require any additional decorative covering either over the suspension membrane  100  or the perimeter frame  200  and associated parts. The omission of decorative covers may lead to additional weight and cost savings. 
         [0044]    A suspension headrest  1  may also offer additional comfort options to the passenger while being lighter and more compact that traditional headrests. For example, the suspension headrest  1  may include articulation points such that lateral portions of the suspension headrest  1  may fold forward to help provide lateral support to a passenger&#39;s head. In certain embodiments, the suspension headrest  1  may have a single suspension membrane  100 , or it may consist of three individual sections with perimeter frames  200  and suspension membranes  100  connected to form a single suspension headrest  1 . 
         [0045]    Any of the above described components, parts, or embodiments may take on a range of shapes, sizes, or materials as necessary for a particular application of the described invention. The components, parts, or mechanisms of the described invention may be made of any materials selected for the suitability in use, cost, or ease of manufacturing. Materials including, but not limited to aluminum, stainless steel, fiber reinforced plastics, carbon fiber, composites, polycarbonate, polypropylene, other metallic materials, or other polymers may be used to form any of the above described components. 
         [0046]    Different arrangements of the components depicted in the drawings or described above, as well as components and steps not shown or described are possible. Similarly, some features and sub-combinations are useful and may be employed without reference to other features and sub-combinations. Embodiments of the invention have been described for illustrative and not restrictive purposes, and alternative embodiments will become apparent to readers of this patent. Accordingly, the present invention is not limited to the embodiments described above or depicted in the drawings, and various embodiments and modifications may be made without departing from the scope of the claims below.