Patent Description:
Publication <CIT> discloses an earpad cover made of one piece of knitted fabric.

Publication <CIT> discloses an earpad having coated outer and inner regions while leaving a region which is in contact with a user's head permeable to air.

Various approaches are described herein for, among other things, providing an improved construction for an earcup that may be incorporated into a headphone device. For instance, an earcup includes a cover constructed of a seamless three-dimensional cover.

There is provided a headphone earcup and a method of making a headphone earcup according to the claims.

It is noted that the invention is not limited to the specific embodiments described in the Detailed Description and/or other sections of this document. Such embodiments are presented herein for illustrative purposes only.

The accompanying drawings, which are incorporated herein and form part of the specification, illustrate embodiments of the present invention and, together with the description, further serve to explain the principles involved and to enable a person skilled in the relevant art(s) to make and use the disclosed technologies.

The features and advantages of the disclosed technologies will become more apparent from the detailed description set forth below when taken in conjunction with the drawings, in which like reference characters identify corresponding elements throughout.

The following detailed description refers to the accompanying drawings that illustrate example embodiments of the present invention. However, the scope of the present invention is not limited to these embodiments, but is instead defined by the appended claims.

References in the specification to "one embodiment," "an embodiment," "an example embodiment," or the like, indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic.

Example embodiments described herein provide improvements over known earcups for headphone devices, such as audio headphones or hearing protection headphones. Example embodiments of the headphone device include an earcup construction that results in improved fit, comfort, performance, manufacturability, and serviceability of the earcup.

Earcups included in headphone devices are often manufactured using a multi-piece cover construction. Such a construction requires multiple pieces to be formed separately and coupled together to form the cover. The multiple pieces are coupled by forming seams and then the combined pieces are fit over a cover support that provides the shape of the earcup. The cover support must be formed to provide relief, such as in the form of a groove, to prevent the seams from creating a discontinuous and/or undesired outer contour of the earcup. As a result, the production of the cover requires multiple unnecessary and time-consuming steps that can be avoided using a seamless three-dimensional cover in accordance with at least one embodiment.

Additionally, the multi-piece construction of the cover allows for a common failure mode of earcups, i.e., the delamination of the seams. That failure mode can be avoided by employing a seamless three-dimensional cover in accordance with at least one embodiment. In particular, the seams are oftentimes formed by welding, adhering and/or stitching multiple cover pieces together. With repeated use, and the associated application of heat and moisture, the seams can delaminate. The removal of the seams in the seamless three-dimensional cover avoids the failure mode and provides the ability to tune portions of the earcup cover for desired fit, comfort, and/or performance.

<FIG> illustrate at least one embodiment of a headphone device <NUM> that may include an earcup in accordance with at least one embodiment. The headphone device <NUM> comprises a headband <NUM>, and acoustic assemblies <NUM> (e.g., acoustic assemblies <NUM>-<NUM> and <NUM>-<NUM>) coupled to terminal ends <NUM> (e.g., terminal ends <NUM>-<NUM> and <NUM>-<NUM>) of the headband <NUM>. The headband <NUM> is configured to space the acoustic assemblies <NUM> from each other. The headband <NUM> can be flexible to allow for adjustment in the spacing and orientation between the acoustic assemblies <NUM> to adjust the fit on a user.

Connectors <NUM> (e.g., connectors <NUM>-<NUM> and <NUM>-<NUM>) movably couple the headband <NUM> to the acoustic assemblies <NUM>. Each of the connectors <NUM> is configured to allow the respective acoustic assembly <NUM> to be oriented to provide an optimal ergonomic fit over a user's ear. Each of the acoustic assemblies <NUM> can be coupled to the headband <NUM> so that the respective acoustic assembly can be rotated relative to the headband <NUM> over any span. In at least one embodiment, the acoustic assembly can rotate relative to the headband <NUM> over a span of about <NUM>°. In some embodiments, the acoustic assembly can rotate relative to the headband <NUM> in a span up to <NUM>°. In some embodiments, the acoustic assembly can rotate relative to the headband <NUM> over a span that is greater than <NUM>°.

The terminal ends <NUM> of the headband <NUM> are spaced so that the acoustic assemblies <NUM> are held in a spaced relationship from each other by the headband <NUM>. The spaced relationship between the acoustic assemblies <NUM> places the acoustic assemblies in a predefined location and orientation so that earcups can be positioned over a user's ears. In that position, the acoustic assemblies <NUM> are configured to direct an audible signal toward the user's ears (e.g., using audio headphones) and/or to prevent high-intensity sound from reaching the user's ears (e.g., using hearing protection headphones, or audio headphones with noise cancellation).

The headband <NUM> comprises an elongate body that is interposed between the acoustic assemblies <NUM>. In at least one embodiment, the headband <NUM> is configured to rest on the top of a user's head, such as on the rearward portion of the user's frontal bone, on the forward portion of the user's parietal bone, and/or at a location where the front bone meets the parietal bone. It should be appreciated that the headband can be configured to rest over any portion of the user's head when the headphone device is worn by the user.

The headband <NUM> is configured to provide a desired fit of the headphone device <NUM> on the user. The shape and materials used in the construction of the headband <NUM> can be selected to provide the desired fit of the headphone device <NUM>. In at least one embodiment, the shape of the headband <NUM> is arcuate and sized to correspond to the contour of a user's head. Additionally, the headband <NUM> can comprise a pad <NUM> that is oriented on an inner portion of the headband <NUM> so that the pad <NUM> is positioned to abut the user's head. In at least one embodiment, the pad <NUM> is removeable so that it can be easily cleaned and/or replaced by the user.

The headband <NUM> can also include at least a portion that is flexible. The flexible portion of the headband <NUM> forms a spring between the acoustic assemblies <NUM>. The head band <NUM> can be configured to provide a spring force that is selected so that the acoustic assemblies <NUM> exert a predefined force on the sides of a user's head. In at least one embodiment, the spring force is selected so that the predefined force results in earcups <NUM> (e.g., earcups <NUM>-<NUM> and <NUM>-<NUM>) of the acoustic assemblies <NUM> providing seals against the user's head that reduces leakage of ambient noise past the earcups and into the user's ears. Additionally, the spring force can be selected to provide friction between the user's head and the acoustic assemblies <NUM> to reduce relative motion between the user's head and the headphone device <NUM>. In at least one embodiment, the entire headband <NUM> is constructed to be flexible.

The headband <NUM> can also be configured to provide a desired fit by including a length adjustment feature. As an example, the headband <NUM> can comprise one or more telescoping joints <NUM> that permit a user to alter the length of the headband <NUM>. In at least one embodiment, the headband <NUM> comprises a discontinuous elongate body that is constructed from a plurality of components, such as a crown member 102a, a first arm member 102b, and a second arm member 102c. The headband <NUM> can further comprise an extension member that extends across each discontinuity in the elongate body. The extension member can be slidably coupled across the discontinuity between the headband components to at least one of the adjacent portions of the elongate body thereby forming the telescoping joint <NUM>. Additionally, the extension member and/or the elongate body can comprise détente features to provide defined length settings and can provide audible and/or tactile feedback to a user while the user alters the length of the headband <NUM>.

Additionally, the headband <NUM> can form a housing for electronics included in the headphone device <NUM>. For example, the headband <NUM> can define a cavity that houses circuitry. The cavity can also provide a conduit for wiring included in the construction of the headphone device <NUM>.

In at least one embodiment, each acoustic assembly <NUM> includes the earcup <NUM>, a housing <NUM> (e.g., housings <NUM>-<NUM> and <NUM>-<NUM>), and a yoke <NUM> (e.g., yokes <NUM>-<NUM> and <NUM>-<NUM>). The earcup <NUM> is shaped and sized to provide a desired fit over, or on, a user's ear. The earcup <NUM> can define a sound hole <NUM> and can be constructed to define performance characteristics, such as acoustic properties (e.g., audio transparency) and comfort properties (e.g., cushioning, stiffness, or surface texture). The earcup <NUM> can include a cover <NUM> (e.g., covers <NUM>-<NUM> and <NUM>-<NUM>) that at least partially encloses a cover support (e.g., an earpad), a coupling member, a screen support <NUM>, and a screen <NUM>.

The cover <NUM> is constructed as a seamless three-dimensional body. The cover <NUM> is knit. The cover <NUM> is formed from a continuous contoured fabric of interlocking fibers or yarn. The three-dimensional shape can provide a contour that defines the overall annular shape of the cover <NUM>. In some embodiments, the three-dimensional shape results in the cover defining an annular cavity and the cover support can be disposed in the annular cavity.

As used herein "annular" is not limited to circular shapes for either the exterior shape or the interior shape and is intended to describe a generally ring shape that may or may not include circular shapes. An annular body may have an exterior shape that is different from an interior shape. Additionally, the centroids of the interior shape and the exterior shape need not coincide so that the annulus can have a width that varies at locations around the circumference. For example, the outer perimeter can provide an exterior shape that may be a circle, an oval, a polygon, or irregular. Regardless of the exterior shape, the interior shape can be a circle, an oval, a polygon, or irregular. In the example embodiment shown in <FIG>, the earcup <NUM> is annular and includes a circular exterior shape and an ovular interior shape.

The cover <NUM> includes an outer portion <NUM> (e.g., outer portions <NUM>-<NUM> and <NUM>-<NUM>), an inner portion <NUM>, and an intermediate portion <NUM> (e.g., intermediate portions <NUM>-<NUM> and <NUM>-<NUM>). The outer portion <NUM> forms the radially outermost surface of the cover <NUM> of the earcup <NUM> relative to a central axis A1 of the acoustic assembly <NUM>. The inner portion <NUM> forms an inner side wall of the cover <NUM> of the earcup <NUM> and is disposed radially inward from the outer portion <NUM> relative to the central axis A1 so that it forms the side wall of the sound hole <NUM>.

The intermediate portion <NUM> extends between the outer portion <NUM> and the inner portion <NUM> and generally provides a contact, or ear-abutting, surface of the cover <NUM>. The intermediate portion <NUM> includes an aperture that defines a perimeter of an opening of the sound hole <NUM> closest to a user's ear. The intermediate portion <NUM> has a stiffness that is different from a stiffness of the outer portion <NUM> and/or a stiffness of the inner portion <NUM> so that it provides cushioning to a user. As will be described in greater detail, the difference in stiffness is due to at least one of a different knit pattern or a different fabric material in the region of the intermediate portion <NUM>.

Regions of the continuous fabric forming the outer portion, the inner portion, and the intermediate portion in each of the example cover embodiments described herein are configured to provide different acoustic transparency values. For example, the outer portion <NUM> can be configured to have a first acoustic transparency value, the inner portion <NUM> can be configured to have a second acoustic transparency value, and the intermediate portion <NUM> can be configured to have a third acoustic transparency value. In at least one embodiment, the first acoustic transparency value is different than at least one of the second acoustic transparency value or the third acoustic transparency value. In at least one embodiment, the first acoustic transparency value is lower than at least one of the second acoustic transparency value and the third acoustic transparency value.

The cover support forms an ear pad that can provide cushioning to a user. The cover support can be shaped to complement the shape of the annular cavity defined by the cover <NUM>. In some embodiments, the cover <NUM> is constructed so that it is rigid enough to maintain the desired shape and flexibility without being supported by a cover support, in.

The coupling member provides an interface between the housing <NUM> and the earcup <NUM>. In some embodiments, the coupling member is configured to provide a removable coupling between the housing <NUM> and the earcup <NUM> so that the earcup <NUM> can be removed and/or replaced. The coupling member and/or the housing <NUM> can include coupling features that can be configured to retain the earcup <NUM> with the housing <NUM>. The coupling features can be configured to provide an interlocking by relative rotation between the earcup <NUM> and the housing <NUM>. Alternatively, snap fits, press fits, interference fits, or any other interlocking mechanism that prevents the earcup <NUM> from separating from the housing <NUM> during use can be employed.

The screen support <NUM> provides a support structure for the screen <NUM>. The screen support <NUM> can provide a flange for coupling the screen <NUM> to the other components of the earcup <NUM>. The screen support <NUM> can be a separate component, or it can be integrated into another component, such as the cover <NUM>. The screen support <NUM> can be rigid, or semi-rigid, so that the screen support <NUM> provides a structure that supports and orients the screen <NUM>. The screen support <NUM> can have a stiffness that is greater than a stiffness of the screen <NUM>. In at least one embodiment, the screen support <NUM> has a stiffness that is greater than a stiffness of the intermediate portion <NUM> of the cover <NUM>. The screen support <NUM> can be an annular member so that it forms an aperture that allows an audible signal to pass through the screen support <NUM> and to be directed toward the user's ear. The screen support <NUM> can be contoured or planar.

The screen <NUM> can be provided in the acoustic assembly <NUM> to extend across a portion of the sound hole <NUM> that is defined by the earcup <NUM>. In some embodiments, the screen <NUM> is configured to alter the acoustic characteristics of the earcup <NUM>. In some embodiments, the screen is configured to provide a comfort property, such as by providing ventilation. The screen <NUM> can also, or alternatively, be configured to protect components housed in the housing <NUM> when the earcup <NUM> is attached. For example, the screen <NUM> can be configured to prevent the ingress of moisture and/or debris into the housing <NUM>.

The housing <NUM> provides a structure for supporting and protecting components of the acoustic assembly <NUM> such as audio components. For example, the audio components can include an audio output device, such as a digital or analog speaker, and electronics that support the audio output device. The components can also include controls and supporting control electronics for controlling volume, connectivity, etc..

The yoke <NUM> is an optional component that can be used to couple the housing <NUM> to the connector <NUM> to provide improved fit for a user by allowing additional adjustment of the position of the acoustic assembly <NUM> relative to the headband <NUM>. For example, the connector <NUM> can rotatably couple the yoke <NUM> to the headband <NUM> to permit relative rotation about a first axis of rotation between the yoke <NUM> and the headband <NUM>. The yoke <NUM> can also be rotatably coupled to the housing <NUM> to permit relative rotation about a second axis of rotation between the yoke <NUM> and the housing <NUM> that is different than the first axis of rotation to provide additional adjustment for a user to fit the headphone device <NUM>. The yoke <NUM> can have many different configurations that provide a linkage between the connector <NUM> and the housing <NUM> and can be omitted if desired.

The acoustic assemblies <NUM> can have a variety of configurations. The acoustic assemblies can be configured to provide an audible signal and/or to limit the exposure of the user's ear to noise. In at least one embodiment, the headphone device <NUM> is audio headphones and each acoustic assembly is configured as a speaker assembly. The speaker assembly may, or may not, also incorporate noise-cancellation technology. In at least one embodiment, the headphone device <NUM> is hearing protection headphones and each acoustic assembly can be configured as a sound earmuff assembly. The sound earmuff assembly may, or may not, also incorporate noise-cancellation technology.

<FIG> illustrates an example acoustic assembly <NUM> that includes an earcup <NUM> (also shown in <FIG>). In some embodiments, the acoustic assembly <NUM> is the acoustic assembly <NUM>. The acoustic assembly <NUM> includes an earcup <NUM>, and a housing <NUM>. The earcup <NUM> is shaped and sized to provide a desired fit over, or on, a user's ear. The earcup <NUM> is generally annular and defines a sound hole <NUM> that extends in the direction of a central axis A1 of the acoustic assembly <NUM>. The earcup <NUM> can be constructed to define performance characteristics, such as acoustic properties (e.g., audio transparency) and comfort properties (e.g., stiffness, or surface texture).

The earcup <NUM> can be assembled from a cover <NUM> that at least partially encloses a cover support <NUM> (e.g., an earpad), a coupling member <NUM>, a screen support <NUM>, and a screen <NUM>. The cover <NUM> is constructed as a seamless three-dimensional body. The cover <NUM> is knit. The cover <NUM> is formed from a continuous contoured fabric of interlocking fibers or yarn. The three-dimensional shape can provide a contour that defines an overall annular shape of the cover <NUM>. In example embodiments, the three-dimensional shape results in the cover defining an annular cavity and the cover support <NUM> can be disposed in the annular cavity. In the illustrated embodiment, the cover <NUM> is initially constructed separate from each of the coupling member <NUM>, the screen support <NUM>, and the screen <NUM>, but it should be appreciated that any, or all, of those components can be integrally formed as part of the cover, as will be described in greater detail with regard to additional embodiments.

The cover <NUM> includes an outer portion <NUM>, an inner portion <NUM>, and an intermediate portion <NUM>. The region of the fabric forming each of the outer portion <NUM>, the inner portion <NUM>, and the intermediate portion <NUM> can be tailored to provide desired performance characteristics for each of the portions. For example, even though the cover <NUM> is constructed as a seamless three-dimensional cover formed from a continuous fabric, different regions of the fabric can be constructed to provide different performance characteristics, such as by including different knit patterns and/or different materials.

The outer portion <NUM> forms the radially outermost surface of the cover <NUM> of the earcup <NUM> relative to a central axis A1 of the acoustic assembly <NUM>. The outer portion <NUM> forms the portion of the cover <NUM> that is most exposed to environmental conditions, such as ambient noise, moisture and debris, when the acoustic assembly <NUM> is worn by a user. In at least one embodiment, a region of the continuous fabric forming the outer portion <NUM> includes a knit pattern having a stitch density that is high enough to reduce the acoustic transparency of the outer portion <NUM>. In at least one other example embodiment, the region of the continuous fabric forming the outer portion <NUM> is finished to provide moisture resistance and/or resistance to becoming soiled.

The inner portion <NUM> forms the radially innermost surface of the cover <NUM> of the earcup <NUM> relative to the central axis A1 of the acoustic assembly <NUM>. The inner portion <NUM> forms a side wall of the sound hole <NUM> and is most exposed to a user's inner ear when the acoustic assembly <NUM> is worn by a user. In an example embodiment, a region of the continuous fabric forming the inner portion <NUM> includes a knit pattern having a stitch density that is low enough to allow ventilation of heat and moisture from the sound hole <NUM> and away from the user's ear. In at least one other example embodiment, the region of the continuous fabric forming the inner portion <NUM> is finished to provide moisture resistance.

The intermediate portion <NUM> extends between the outer portion <NUM> and the inner portion <NUM> and forms a surface of the cover <NUM> that is spaced from the housing <NUM> in a direction parallel to the central axis A1 of the acoustic assembly <NUM>. The intermediate portion <NUM> provides an ear-abutting surface that contacts a user's head when the acoustic assembly <NUM> is worn by a user. In some embodiments, a region of the continuous fabric forming the intermediate portion <NUM> includes a knit pattern having a stitch density that is low enough to allow ventilation of heat and moisture away from the user. In some embodiments, the region of the continuous fabric forming the intermediate portion <NUM> is finished to provide moisture resistance, soiling resistance, and/or to provide desired softness or suppleness. In some embodiments, the region of the continuous fabric forming the intermediate portion <NUM> includes thermoset and/or thermoplastic filaments that can be used to provide a desired flexibility of the intermediate portion <NUM> so that the cover <NUM> is constructed to provide cushioning to the user during use.

The cover support <NUM> is formed as an ear pad that can provide a cushioning structure that fills at least a portion of the annular cavity defined by the cover <NUM>. In at least one embodiment, the cover support <NUM> entirely fills the annular cavity defined by the cover <NUM>. In at least one embodiment, the cover support <NUM> fills only a portion of the annular cavity defined by the cover <NUM>. The outer surface of the cover support <NUM> can be shaped to complement the inner shape of the annular cavity defined by the cover <NUM>. The seamless construction of the continuous fabric of the cover <NUM> permits the construction of the cover support <NUM> to be simplified. In particular, because there are no seams between components forming the cover, there is no need to include relief slots or grooves in the cover support <NUM> that would otherwise receive the seams and allow for a smoother outer contour of the cover.

The coupling member <NUM> provides an interface between the housing <NUM> and the earcup <NUM>. In the illustrated embodiment, the coupling member <NUM> and the housing <NUM> include coupling features that are configured to retain the earcup <NUM> with the housing <NUM>. For example, the coupling features can include features that interlock when the parts are rotated relative to each other. For example, the coupling member <NUM> can include tapered ribs <NUM> that extends radially inward, and the housing <NUM> can include a tapered slot and/or a locking tab <NUM> that slidably abuts the tapered rib <NUM> so that relative rotation between the coupling member <NUM> and the housing <NUM> draw the coupling member <NUM> and the housing <NUM> together.

The screen support <NUM> provides a support structure for the screen <NUM>. The screen support <NUM> can provide a flange for coupling the screen <NUM> to the other components of the earcup <NUM>. The screen support <NUM> can be rigid, or semi-rigid, so that the screen support <NUM> provides a structure that orients the screen <NUM>. For example, the screen support <NUM> can have a stiffness greater than a stiffness of the screen <NUM>, and/or greater than a stiffness of the intermediate portion <NUM>. The screen support <NUM> can be an annular member so that it forms an aperture that allows an audible signal to pass through the screen support <NUM> and to be directed toward the user's ear. The screen support <NUM> can be contoured or planar.

The screen <NUM> can be provided in the acoustic assembly <NUM> to extend across a portion of the sound hole <NUM> that is defined by the earcup <NUM>. The screen <NUM> can be disposed at any location in the sound hole <NUM>, such as at an end of the sound hole <NUM> closest to the housing <NUM> and the coupling member <NUM>. In some embodiments, the screen <NUM> is configured to alter the acoustic characteristics of the earcup <NUM>. In some embodiments, the screen <NUM> is configured to provide ventilation so that moisture and/or heat can escape from the sound hole <NUM> and be directed away from the user's ear. The screen <NUM> can also, or alternatively, be configured to protect components housed in the housing <NUM> when the earcup <NUM> is attached. For example, the screen <NUM> can be configured to prevent the ingress of moisture and/or debris into the housing <NUM>.

The housing <NUM> provides a structure for supporting and protecting components of the acoustic assembly <NUM> such as audio components. For example, the audio components can include an audio output device, such as a digital or analog speaker <NUM>, and electronics that support the audio output device. The components can also include controls and supporting control electronics for controlling volume, connectivity, etc..

Referring to <FIG>, another example embodiment of an earcup that can be incorporated into an acoustic assembly, such as by replacing earcup <NUM> of acoustic assembly <NUM>, will be described. The earcup <NUM> includes a cover <NUM> that at least partially encloses a cover support <NUM> (e.g., an earpad), a coupling member <NUM>, a screen support <NUM>, and a screen <NUM>. Similar to other example embodiments, the cover <NUM> is constructed as a seamless three-dimensional body. The cover <NUM> is knit. The cover <NUM> is formed from a continuous contoured fabric of interlocking fiber or yarn. The three-dimensional shape can provide a contour that defines an overall annular shape of the cover <NUM>. In some embodiments, the three-dimensional shape results in the cover defining an annular cavity and the cover support <NUM> can be disposed in the annular cavity. In the illustrated embodiment, the cover <NUM> is constructed so that the screen support <NUM> is integrated into the continuous construction, but separate from each of the coupling member <NUM>, and the screen <NUM>.

The cover <NUM> includes an outer portion <NUM>, an inner portion <NUM>, an intermediate portion <NUM>, and a screen support portion <NUM>. The region of the fabric forming each of the outer portion <NUM>, the inner portion <NUM>, the intermediate portion <NUM>, and the screen support portion <NUM> can be tailored to provide desired performance characteristics for each of the portions. For example, even though the cover <NUM> is constructed as a seamless three-dimensional cover formed from a continuous fabric, different regions of the fabric can be constructed to provide different performance characteristics, such as by including different knit patterns and/or different materials.

The outer portion <NUM> forms the radially outermost surface of the cover <NUM> of the earcup <NUM> relative to a central axis A1 of an acoustic assembly. The outer portion <NUM> forms the portion of the cover <NUM> that is most exposed to environmental conditions, such as ambient noise, moisture and debris, when the acoustic assembly is worn by a user. In at least one embodiment, a region of the continuous fabric forming the outer portion <NUM> includes a knit pattern having a stitch density that is high enough to reduce the acoustic transparency of the outer portion <NUM>. In some embodiments, the region of the continuous fabric forming the outer portion <NUM> is finished to provide moisture resistance and/or resistance to becoming soiled.

The inner portion <NUM> forms the radially innermost surface of the cover <NUM> of the earcup <NUM> relative to the central axis A1 of the acoustic assembly. The inner portion <NUM> forms a side wall of a sound hole <NUM> and is most exposed to a user's inner ear when the acoustic assembly is worn by a user. In at least one embodiment, a region of the continuous fabric forming the inner portion <NUM> includes a knit pattern having a stitch density that is low enough to allow ventilation of heat and moisture from the sound hole <NUM> and away from the user's ear. In some embodiments, the region of the continuous fabric forming the inner portion <NUM> is finished to provide moisture resistance.

The intermediate portion <NUM> extends between the outer portion <NUM> and the inner portion <NUM> and forms a surface of the cover <NUM> that is spaced from a housing of the acoustic assembly in a direction parallel to the central axis A1. The intermediate portion <NUM> provides an ear-abutting surface that contacts a user's head when the acoustic assembly is worn by a user. In at least one example embodiment, a region of the continuous fabric forming the intermediate portion <NUM> includes a knit pattern having a stitch density that is low enough to allow ventilation of heat and moisture away from the user. In some embodiments, the region of the continuous fabric forming the intermediate portion <NUM> is finished to provide moisture resistance, soiling resistance, and/or to provide desired softness or suppleness. In some embodiments, the region of the continuous fabric forming the intermediate portion <NUM> includes filaments that can be shaped using heat and used to provide a desired flexibility of the intermediate portion <NUM> so that the cover <NUM> is constructed to provide cushioning to the user during use.

The screen support <NUM> of earcup <NUM> is integrated into the cover <NUM>. For example, the screen support <NUM> is formed as part of the seamless three-dimensional cover and formed by a region of the continuous contoured fabric of the cover <NUM>. The screen support <NUM> provides a support for the screen <NUM>. The screen support <NUM> can provide a flange for coupling the screen <NUM> to the other components of the earcup <NUM>. The screen support <NUM> can be rigid, or semi-rigid, so that the screen support <NUM> provides a structure that orients the screen <NUM>. For example, the screen support <NUM> can have a stiffness greater than a stiffness of the screen <NUM>, and/or greater than a stiffness of the intermediate portion <NUM>. The screen support <NUM> can be an annular member so that it forms an aperture that allows an audible signal to pass through the screen support <NUM> and to be directed toward the user's ear.

The cover support <NUM> can be formed as an ear pad that provides a cushioning structure that fills at least a portion of the annular cavity defined by the cover <NUM>. In some embodiments, the cover support <NUM> entirely fills the annular cavity defined by the cover <NUM>. In some embodiments, the cover support <NUM> fills only a portion of the annular cavity defined by the cover <NUM>. The outer surface of the cover support <NUM> can be shaped to complement the inner shape of the annular cavity defined by the cover <NUM>.

The coupling member <NUM> provides an interface between a housing of the acoustic assembly and the earcup <NUM>. The coupling member <NUM> includes coupling features that are configured to interact with the housing to retain the earcup <NUM> with the housing. For example, the coupling member <NUM> can include tapered ribs <NUM> that are configured to interact with and engage coupling features on the housing, such as locking tabs, to couple the parts.

The screen <NUM> can be provided in the acoustic assembly to extend across a portion of the sound hole <NUM> that is defined by the earcup <NUM>. The screen <NUM> can be disposed at any location in the sound hole <NUM>, such as at an end of the sound hole <NUM> closest to the coupling member <NUM>. In some embodiments, the screen <NUM> is configured to alter the acoustic characteristics of the earcup <NUM>. In some embodiments, the screen <NUM> is configured to provide ventilation so that moisture and/or heat can escape from sound hole <NUM> so that moves away from the user's ear. The screen <NUM> can also, or alternatively, be configured to protect components housed in a housing included in the acoustic assembly. For example, the screen <NUM> can be configured to prevent the ingress of moisture and/or debris into the housing.

Referring to <FIG>, another example embodiment of an earcup that can be incorporated into an acoustic assembly, such as by replacing earcup <NUM> of acoustic assembly <NUM>, will be described. The earcup <NUM> includes a cover <NUM> that at least partially encloses a cover support <NUM> (e.g., an ear pad), a coupling member <NUM>, and a screen <NUM>. Similar to other example embodiments, the cover <NUM> is constructed as a seamless three-dimensional body. The cover <NUM> is knit. The cover <NUM> is formed from a continuous contoured fabric of interlocking fibers or yarn. The three-dimensional shape can provide a contour that defines an overall annular shape of the cover <NUM>. In example embodiments, the three-dimensional shape results in the cover defining an annular cavity and the cover support <NUM> can be disposed in the annular cavity. In the illustrated embodiment, the cover <NUM> is constructed so that the screen <NUM> is integrated into the continuous construction, and the earcup <NUM> does not include a screen support.

The cover <NUM> includes an outer portion <NUM>, an inner portion <NUM>, an intermediate portion <NUM>, and a screen portion <NUM>. The region of the fabric forming each of the outer portion <NUM>, the inner portion <NUM>, the intermediate portion <NUM>, and the screen portion <NUM> can be tailored to provide desired performance characteristics for each of the portions. For example, even though the cover <NUM> is constructed as a seamless three-dimensional cover formed from a continuous fabric, different regions of the fabric can be constructed to provide different performance characteristics, such as by including different knit patterns and/or different materials.

The outer portion <NUM> forms the radially outermost surface of the cover <NUM> of the earcup <NUM> relative to a central axis A1 of an acoustic assembly. The outer portion <NUM> forms the portion of the cover <NUM> that is most exposed to environmental conditions, such as ambient noise, moisture and debris, when the acoustic assembly is worn by a user. In some embodiments, a region of the continuous fabric forming the outer portion <NUM> includes a knit pattern having a stitch density that is high enough to reduce the acoustic transparency of the outer portion <NUM>. In some embodiments, the region of the continuous fabric forming the outer portion <NUM> is finished to provide moisture resistance and/or resistance to becoming soiled.

The inner portion <NUM> forms the radially innermost surface of the cover <NUM> of the earcup <NUM> relative to the central axis A1 of the acoustic assembly. The inner portion <NUM> forms a side wall of a sound hole <NUM> and is most exposed to a user's inner ear when the acoustic assembly is worn by a user. In some embodiments, a region of the continuous fabric forming the inner portion <NUM> includes a knit pattern having a stitch density that is low enough to allow ventilation of heat and moisture from the sound hole <NUM> and away from the user's ear. In some embodiments, the region of the continuous fabric forming the inner portion <NUM> is finished to provide moisture resistance.

The intermediate portion <NUM> extends between the outer portion <NUM> and the inner portion <NUM> and forms a surface of the cover <NUM> that is spaced from a housing of the acoustic assembly in a direction parallel to the central axis A1. The intermediate portion <NUM> provides an ear-abutting surface that contacts a user's head when the acoustic assembly is worn by a user. In some embodiments, a region of the continuous fabric forming the intermediate portion <NUM> includes a knit pattern having a stitch density that is low enough to allow ventilation of heat and moisture away from the user. In some embodiments, the region of the continuous fabric forming the intermediate portion <NUM> is finished to provide moisture resistance, soiling resistance, and/or to provide desired softness or suppleness. In some embodiments, the region of the continuous fabric forming the intermediate portion <NUM> includes filaments that can be shaped using heat to provide a desired flexibility of the intermediate portion <NUM> so that the cover <NUM> is constructed to provide cushioning to the user during use.

The screen <NUM> of earcup <NUM> is integrated into the cover <NUM>. The screen <NUM> can be provided in the acoustic assembly to extend across a portion of a sound hole <NUM> that is defined by the earcup <NUM>. The screen <NUM> extends from an edge of the inner portion <NUM> and across the sound hole <NUM>. As illustrated, the screen <NUM> is disposed at an end of the sound hole <NUM> closest to the coupling member <NUM>. In some embodiments, the screen <NUM> is configured to alter the acoustic characteristics of the earcup <NUM>. In some embodiments, the screen <NUM> is configured to provide ventilation so that moisture and/or heat can escape from sound hole <NUM> so that moves away from the user's ear. The screen <NUM> can also, or alternatively, be configured to protect components housed in a housing included in the acoustic assembly. For example, the screen <NUM> can be configured to prevent the ingress of moisture and/or debris into the housing.

The coupling member <NUM> provides an interface between a housing of the acoustic assembly and the earcup <NUM>. The coupling member <NUM> includes coupling features that are configured to interact with the housing to retain the earcup <NUM> with the housing. For example, the coupling member <NUM> can include tapered ribs <NUM> that are configured to interact with coupling features, such as locking tabs, on the housing of the acoustic assembly to couple the parts.

The earcup <NUM> can be assembled from a cover <NUM> that at least partially encloses a cover support <NUM> (e.g., an ear pad), a coupling member <NUM>, a screen support <NUM>, and a screen <NUM>. The cover <NUM> is constructed as a seamless three-dimensional body. The cover <NUM> is knit. The cover is formed from a continuous contoured fabric of interlocking yarn. The three-dimensional shape can provide a contour that defines an overall annular shape of the cover <NUM>. In some embodiments, the three-dimensional shape results in the cover defining an annular cavity and the cover support <NUM> can be disposed in the annular cavity. Additionally, in the illustrated embodiment, the cover <NUM> is constructed so that the coupling member <NUM> is integrated into the continuous construction of the cover <NUM>.

The cover <NUM> includes an outer portion <NUM>, an inner portion <NUM>, an intermediate portion <NUM>, and the coupling member <NUM>. The region of the fabric forming each of the outer portion <NUM>, the inner portion <NUM>, the intermediate portion <NUM>, and the coupling member <NUM> can be tailored to provide desired performance characteristics for each of the portions. For example, even though the cover <NUM> is constructed as a seamless three-dimensional cover formed from a continuous fabric, different regions of the fabric can be constructed to provide different performance characteristics, such as by including different knit patterns and/or different materials.

The outer portion <NUM> forms the radially outermost surface of the cover <NUM> of the earcup <NUM> relative to a central axis A1 of the acoustic assembly <NUM>. The outer portion <NUM> forms the portion of the cover <NUM> that is most exposed to environmental conditions, such as ambient noise, moisture and debris, when the acoustic assembly <NUM> is worn by a user. In some embodiments, a region of the continuous fabric forming the outer portion <NUM> includes a knit pattern having a stitch density that is high enough to reduce the acoustic transparency of the outer portion <NUM>. In some embodiments, the region of the continuous fabric forming the outer portion <NUM> is finished to provide moisture resistance and/or resistance to becoming soiled.

The inner portion <NUM> forms the radially innermost surface of the cover <NUM> of the earcup <NUM> relative to the central axis A1 of the acoustic assembly <NUM>. The inner portion <NUM> forms a side wall of the sound hole <NUM> and is most exposed to a user's inner ear when the acoustic assembly <NUM> is worn by a user. In some embodiments, a region of the continuous fabric forming the inner portion <NUM> includes a knit pattern having a stitch density that is low enough to allow ventilation of heat and moisture from the sound hole <NUM> and away from the user's ear. In some embodiments, the region of the continuous fabric forming the inner portion <NUM> is finished to provide moisture resistance.

The intermediate portion <NUM> forms a surface of the cover <NUM> that is spaced from the housing <NUM> in a direction parallel to the central axis A1 of the acoustic assembly <NUM>. The intermediate portion <NUM> provides an ear-abutting surface that contacts a user's head when the acoustic assembly <NUM> is worn by a user. In some embodiments, a region of the continuous fabric forming the intermediate portion <NUM> includes a knit pattern having a stitch density that is low enough to allow ventilation of heat and moisture away from the user. In some embodiments, the region of the continuous fabric forming the intermediate portion <NUM> is finished to provide moisture resistance, soiling resistance, and/or to provide desired softness or suppleness. In some embodiments, the region of the continuous fabric forming the intermediate portion <NUM> includes filaments that can be shaped using heat and used to provide a desired flexibility of the intermediate portion <NUM> so that the cover <NUM> is constructed to provide cushioning to the user during use.

The coupling member <NUM> provides an interface between the housing <NUM> and the earcup <NUM>. In the illustrated embodiment, the coupling member <NUM> is a flange that is formed integrally as a portion of the cover <NUM>. The housing <NUM> includes a coupling feature, such as a coupling flange <NUM>, that is received and retained in an undercut defined by the coupling member <NUM>. The coupling member <NUM> is configured to be flexible enough to stretch over the coupling flange <NUM> and to retain the coupling flange <NUM>. The flexibility of the coupling member <NUM> can be provided by selecting the knit pattern and materials included in that region of the continuous fabric of the cover <NUM>.

The screen support <NUM> provides a support for the screen <NUM>. The screen support <NUM> can provide a flange for coupling the screen <NUM> to the other components of the earcup <NUM>. The screen support <NUM> can be rigid, or semi-rigid, so that the screen support <NUM> provides a structure that orients the screen <NUM>. For example, the screen support <NUM> can have a stiffness greater than a stiffness of the screen <NUM>, and/or greater than a stiffness of the intermediate portion <NUM>. The screen support <NUM> can be an annular member so that it forms an aperture that allows an audible signal to pass through the screen support <NUM> and to be directed toward the user's ear. As illustrated, the screen support <NUM> is planar.

The screen <NUM> can be provided in the acoustic assembly <NUM> to extend across a portion of the sound hole <NUM> that is defined by the earcup <NUM>. The screen <NUM> can be disposed at any location in the sound hole <NUM>, such as at an end of the sound hole <NUM> closest to the housing <NUM> and the coupling member <NUM>. In some embodiments, the screen <NUM> is configured to alter the acoustic characteristics of the earcup <NUM>. In some embodiments, the screen <NUM> is configured to provide ventilation so that moisture and/or heat can escape from sound hole <NUM> so that moves away from the user's ear. The screen <NUM> can also, or alternatively, be configured to protect components housed in the housing <NUM> when the earcup <NUM> is attached. For example, the screen <NUM> can be configured to prevent the ingress of moisture and/or debris into the housing <NUM>.

Similar to previously described example embodiments, the housing <NUM> provides a structure for supporting and protecting components of the acoustic assembly <NUM> such as audio components. For example, the audio components can include an audio output device, such as a speaker <NUM> that can be a digital or analog speaker, and electronics that support the audio output device. The components can also include controls and supporting control electronics for controlling volume, connectivity, etc..

The cover support <NUM> is formed as an ear pad that can provide a cushioning structure that fills at least a portion of the annular cavity defined by the cover <NUM>. In some embodiments, the cover support <NUM> entirely fills the annular cavity defined by the cover <NUM>. In some embodiments, the cover support <NUM> fills only a portion of the annular cavity defined by the cover <NUM>. The outer surface of the cover support <NUM> can be shaped to complement the inner shape of the annular cavity defined by the cover <NUM>.

In each of the example embodiments, the cover can be constructed using synthetic yarn, such as by knitting the cover using a weft-knitting machine so that the knit cover has the three-dimensional shape knit into the structure. In some embodiments, a near final three-dimensional shape of the cover is knit into the structure and a secondary process, such as applying heat, is used to shape the knit cover into the final three-dimensional shape. The secondary process can be performed applying heat while using a shaped cover support, a mold, or another shaping jig. In some embodiments, the synthetic yarn can be extruded. The synthetic yarn can be constructed from a plurality of filaments. In some embodiments, the synthetic yarn is constructed from at least one filament that is formed of a material that can be shaped and set to retain the shape using heat. For example, the yarn can include thermoset and/or thermoplastic polymers. The yarn can be constructed from materials such as multifilament polyester or nylon. The yarn could be made as an extruded polymer, cellulose, or regenerated cellulose fiber. The yarn structure may be single, twisted, texturized or core-spun. To achieve a range of finished textile weights, a yarn size may have a range from 40dtex to 300dtex. To achieve a range of surface textures and structures multiple types of yarns may be used in the same knitted piece.

The cover can also be constructed so that the continuous contoured fabric includes portions having different interlocking constructions, such as knit patterns, to provide different performance characteristics. In some embodiments utilizing weft knits, the patterns can include single knits, double knits, and/or specialized knits that are combined to form the continuous fabric. Examples of single knit patterns include single jersey, and lacoste. Examples of double knit patterns include rib, purl, interlock, cable fabric, bird's eye, cardigans, milano ribs, and pointelle. Examples of specialized knit patterns include intarsia, jacquard jerseys, knitted terry, knitted velour, sliver knit, fleece, and French terry.

In some embodiments, portions include an interlocking construction that provides larger openings where greater audio transparency and/or more ventilation is desired. These openings are achieved by using a missed or a tuck stitch in the knit pattern. In some embodiments, portions include an interlocking construction that provides smaller openings where lower audio transparency and/or less ventilation is desired. Attributes such as mass, density, thickness, compression, porosity and perforation, air permeability and flow resistivity, tortuosity, and surface features can be selected to provide different performance characteristics, such as audio transparency and/or ventilation.

Still further, portions can be finished using different techniques to provide different textures, shapes, appearances, sound absorption, sound transparency, moisture resistance, soiling resistance, etc. For example, finishing processes that can be applied to the cover materials include scouring, heat-setting, post-setting, stiffening, and filling. Additionally, one or more finishes can be applied to the cover materials such as hydrophobic, anti-pilling, anti-static, nonslip, sizing and anti-microbial finishes. The finishing techniques can be mechanical and/or chemical finishing techniques.

In each of the example embodiments, the cover support can be constructed from a flexible material or structure. For example, the cover support can be constructed from a foam material, such as memory foam. In some embodiments, the cover support can completely fill the annular cavity defined by the cover, or partially fill the annular cavity. The cover support can be formed from a foam material having a density in a range of between about <NUM> lb/ft<NUM> and about <NUM> lb/ft<NUM>. In some embodiments, the cover support is formed from a foam material having a density in a range of between about <NUM> lb/ft<NUM> and about <NUM> lb/ft<NUM>. The cover support can be formed from foam materials including viscoelastic polyurethane foam or low-resilience polyurethane foam. In alternative examples, the cover support can be formed as a flexible framework or lattice structure. In some embodiments, the cover support is a tubular member that fills the annular cavity defined by the cover and provides the desired structure and cushioning.

The screen of the earcup can be configured to have portions having different performance characteristics, such as acoustic properties and/or comfort properties, and/or indicia. Referring to <FIG>, an earcup <NUM> includes a cover <NUM> and a screen <NUM>. The cover <NUM> can at least partially encompasses a cover support, such as an ear pad. The screen <NUM> can include screen portions <NUM> having different performance characteristics, such as audio transparency, and/or ventilation. The screen portions <NUM> can be configured to have geometric shapes, such as screen portions <NUM> which are illustrated as having generally polygonal shapes. The screen portions <NUM> can be sized, positioned, and/or configured to have a desired audio transparency to alter the overall performance characteristics of the screen <NUM>. The screen portions <NUM> and remainder of screen <NUM> can have different knit patterns, and/or materials to provide desired performance characteristics.

Referring to <FIG>, in another example embodiment an earcup <NUM> includes a cover <NUM> and a screen <NUM>. The cover <NUM> can at least partially encompasses a cover support, such as an ear pad. The screen <NUM> can include portions having different performance characteristics, such as audio transparency, and/or ventilation. In the illustrated embodiment, screen portions <NUM> of the screen <NUM> are configured to form a grid pattern. The screen portions <NUM> can be sized, positioned, and/or configured to have a desired audio transparency to alter the overall performance characteristics of the screen <NUM>. The screen portions <NUM> and remainder of screen <NUM> can have different knit patterns, and/or materials to provide desired performance characteristics.

Referring to <FIG>, in another example embodiment an earcup <NUM> includes a cover <NUM> and a screen <NUM>. The cover <NUM> can at least partially encompasses a cover support, such as an ear pad. The screen <NUM> can include one or more screen portions <NUM> that form indicia to provide visual information to a user. For example, earcup <NUM> can be configured to be replaceable in a headphone device and the indicia can provide a visual indication of the orientation, which acoustic assembly (i.e., left ear acoustic assembly or a right ear acoustic assembly) of the headphone device corresponds the earcup <NUM>, and/or the brand of the headphone device corresponding to the earcup <NUM>. The indicia can include letters, numbers, logos, and/or symbols. In addition, the screen portions <NUM> can be configured to having different performance characteristics, such as audio transparency, and/or ventilation, such as by including different knit patterns, and/or materials in the cover <NUM>.

<FIG> depicts a flowchart <NUM> of an example method of making an earcup in accordance with at least one embodiment. The method of flowchart <NUM> can be used to construct the various embodiments of <FIG>, for example. Further structural and operational embodiments will be apparent to persons skilled in the relevant art(s) based on the discussion regarding flowchart <NUM>.

As shown in <FIG>, the method of flowchart <NUM> begins at step <NUM>. In step <NUM>, a seamless three-dimensional cover is constructed. The seamless three-dimensional cover is constructed by knitting the cover, such as by using a weft-knitting machine. The seamless three-dimensional cover, e.g., cover <NUM>, is knit. The cover, e.g., cover <NUM>, is formed from a continuous contoured fabric of interlocking yarn, and so that it defines an annular cavity.

At step <NUM>, the cover is coupled to a cover support. The cover is coupled to the cover support so that the cover support is disposed in the annular cavity. For example, the cover <NUM> can be coupled to the cover support <NUM>. The cover support <NUM> is formed as an ear pad that is constructed from a cushion material that is inserted into the annular cavity. The cover can be coupled to the cover support using an adhesive. The adhesive can include thermal adhesive, a pressure adhesive, or a UV cured adhesive. In some embodiments, the cover is ultrasonically welded to the cover support.

At step <NUM>, the cover is coupled to a coupling member. The coupling member provides an interface between the earcup and other structures included in an acoustic assembly. For example, the cover <NUM> can be coupled to a coupling member <NUM>. The coupling member <NUM> can be a ring that includes locking features, such as tapered ribs <NUM>, that engage locking features, such as locking tabs <NUM>, of a housing <NUM> included in an acoustic assembly <NUM>. The coupling member can be coupled to at least one of an outer portion or an inner portion of the cover using an adhesive. The adhesive can include thermal adhesive, a pressure adhesive, or a UV cured adhesive. In some embodiments, the cover is ultrasonically welded to the coupling member.

In some embodiments, the method further comprises finishing the cover to clean the fabric that forms the cover. For example, a lubricant and/or other debris can be present on the fabric after performing a knitting process. The cover can be cleaned to remove the lubricant and/or other debris so that additional finishing processes can be performed, and/or to improve the coupling between the cover and the cover support and/or coupling member.

In some embodiments, the method further comprises finishing the cover to alter the texture of the cover. For example, finishing the cover can include altering the surface features of a filament, the yarn, or the fabric to provide a different feel to a user. In an example, the surface can be roughened to provide a softer feel.

Claim 1:
A headphone earcup (<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>), comprising:
a cover support (<NUM>, <NUM>, <NUM>, <NUM>) forming an ear pad;
a coupling member (<NUM>, <NUM>, <NUM>, <NUM>) configured to couple the earcup to an acoustic assembly (<NUM>) housing (<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>); and
a seamless three-dimensional knit cover (<NUM>, <NUM>, <NUM>, <NUM>) coupled to the coupling member, the knit cover defining an annular cavity and coupled to the ear pad such that the cover support is disposed in the cavity, the knit cover formed from a continuous contoured fabric of interlocking yarn and comprising:
an outer portion (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>) configured to have a first acoustic transparency value;
an inner portion (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>) forming a side wall of a sound hole (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>) and configured to have a second acoustic transparency value; and
an intermediate portion (<NUM>, <NUM>-<NUM>, <NUM>-<NUM>; <NUM>, <NUM>, <NUM>, <NUM>) configured to have a third acoustic transparency value, the intermediate portion extending between the outer portion and the inner portion, and defining a perimeter of the sound hole, wherein the first acoustic transparency value is different than at least one of the second acoustic transparency value or the third acoustic transparency value;
wherein the intermediate portion has a different stiffness than at least one of the inner portion and the outer portion, and wherein the different stiffness is due to at least one of a different knit pattern and a different fabric material.