BACKGROUND

[0001 ] This disclosure relates to a headband that can be used to hold one or more earphones against the head of a wearer.

[0002] Headphones, headsets and the like carry earphones at the ends of a headband that fits over the head of the wearer. The central portion of the headband that fits over the crest of the head is often a cushioned flat elongated tubular portion that is called a "cushion" or "cushion assembly." The cushion assembly needs to flex so that it fits different sized and shaped heads. Flexing can cause folding or bunching of the soft cover of the cushion assembly; this detracts from its comfort and appearance.

SUMMARY

[0003] Folding and bunching of the soft cover of a headband cushion assembly can be lessened with a flexible cover that is able to stretch in two dimensions and is held in tension on the outside of the tubular cushion assembly. To present a clean appearance the cover can be folded into the ends of the cushion assembly and held in place with snap rings that fit into the ends of the tube and push the ends of the cover against the inside of the tube.

[0004] All examples and features mentioned below can be combined in any technically possible way.

[0005] In one aspect, a headband for holding one or more earphones against the head of a wearer includes a slider that supports an earphone, and a generally tubular cushion assembly that has an inside and an outside and that is engaged with the slider so as to allow relative movement of the slider and the cushion assembly, where the slider is located at least in part inside of the cushion assembly. There is a flexible cover that defines at least some of the outside of the cushion assembly, where the cover has an engaging portion that is located inside of the cushion assembly. A retaining member is located at least in part inside of the cushion assembly, where the engaging portion of the cover is located between the retaining member and the inside of the cushion assembly. [0006] Embodiments may include one of the following features, or any combination thereof. The cushion assembly may have an end, and the cover may be located over at least some of the end of the cushion assembly. The retaining member may comprise a ring. The ring may comprise a face that is located just outside of the end of the cushion assembly. The cover may be located between the face of the ring and the end of the cushion assembly. The headband may further comprise mating engaging features in the ring and on the inside of the cushion assembly, where the features engage one another when the ring is seated in the cushion assembly. The mating engaging features may comprise a detent assembly. The detent assembly may comprise a plurality of projections that project inwardly from the inside of the cushion assembly and a plurality of openings in the ring that are each constructed and arranged to receive a projection.

[0007] Embodiments may include one of the above and/or below features, or any

combination thereof. The engaging portion of the cover may be an end of the cover. The cover may be generally tubular such that it covers substantially the entire outside of most or all of the length of the cushion assembly. The headband may further comprise an adhesive between the engaging portion of the cover and the inside of the cushion assembly. The cushion assembly may have two opposed ends, and at least one of the ends may comprise a unitary annular portion or separate member. The cover may comprise a four-way stretch fabric. The cover may be held in tension on the cushion assembly.

[0008] In another aspect, a headband for holding earphones against the head of a wearer includes two sliders, where each slider supports an earphone, and a generally tubular cushion assembly that has an inside and an outside and two opposed ends, where the cushion assembly is engaged with the sliders so as to allow relative movement of the sliders and the cushion assembly. The sliders are located at least in part inside of the cushion assembly. There is a flexible cover comprising a four-way stretch fabric that is held in tension and defines at least a portion of the outside of the cushion assembly, where the cover has two ends that are each located inside of the cushion assembly. There are two retaining rings, where one retaining ring is located in part inside of the cushion assembly at one of its ends and the other retaining ring is located at least in part inside of the cushion assembly at the other of its ends, where the ends of the cover are each located between a retaining ring and the inside of the cushion assembly. There are mating engaging features in each ring and on the inside of the cushion assembly proximate each of its ends, where the features engage one another when the rings are seated in the cushion assembly.

[0009] Embodiments may include one of the above and/or below features, or any combination thereof. The mating engaging features may comprise a detent assembly that comprises a plurality of projections that project inwardly from the inside of the cushion assembly proximate each of its ends, and a plurality of openings in each ring that are each constructed and arranged to receive a projection. The cover may be generally tubular and cover substantially all of the outside of the cushion assembly. Each ring may comprise a face that is located just outside of an end of the cushion assembly. The headband may further comprise an adhesive between the ends of the cover and the inside of the cushion assembly. Each end of the cushion assembly may comprise a unitary annular member.

[0010] In another aspect, a headband for holding earphones against the head of a wearer includes two sliders, where each slider supports an earphone, and a generally tubular cushion assembly that has an inside and an outside and two opposed ends, wherein each end of the cushion assembly comprises a unitary annular member. The cushion assembly is engaged with the sliders so as to allow relative movement of the sliders and the cushion assembly. The sliders are located at least in part inside of the cushion assembly. There is a generally tubular flexible cover comprising a four-way stretch fabric that is held in tension and defines substantially all of the outside of the cushion assembly, where the cover has two ends that are each located inside of the cushion assembly. An adhesive is located between the ends of the cover and the inside of the cushion assembly. There are two retaining rings, where one retaining ring is located in part inside of the cushion assembly at one of its ends and the other retaining ring is located in part inside of the cushion assembly at the other of its ends, where the ends of the cover are each located between a retaining ring and the inside of the cushion assembly and wherein each ring comprises a face that is located just outside of the end of the cushion assembly. There is a detent assembly that comprises a plurality of projections that project inwardly from the inside of the cushion assembly proximate each of its ends and a plurality of openings in each ring that are each constructed and arranged to receive a projection. BRIEF DESCRIPTION OF THE DRAWINGS

[0011 ] Figure 1 shows headphones with the subject headband.

[0012] Figure 2 is an enlarged partial cross-sectional view of an end of the cushion assembly of the headband of figure 1.

[0013] Figure 3 is a side view of a retaining member of the headband.

[0014] Figure 4 is an enlarged cross-sectional view of an end of the cushion assembly of the headband of figure 1.

[0015] Figure 5 is an end view of the cushion assembly.

[0016] Figure 6 is a perspective view of the cushion assembly.

[0017] Figure 7 is a perspective view of one end of the cushion assembly, and a slider engaged with the cushion assembly.

[0018] Figure 8 is a cross-sectional view of the cushion assembly and a slider.

DETAILED DESCRIPTION

[0019] The cover of the cushion assembly of a headband can be maintained such that it does not bunch or wrinkle as the headband is flexed by using a flexible cover that is held in tension using a retaining member that is inserted into the two open ends of the cushion assembly.

[0020] Figure 1 shows headphones 8. Headphones 8 include headband 10 which includes cushion assembly 12 that is constructed and arranged to be placed over the crown of the head of a person. Sliders 14 and 16 support earphones 18 and 20. The sliders engage with cushion assembly 12 in a manner which allows the sliders to be moved in and out of the cushion assembly to adjust the overall length of the headband so that they headphones can sit comfortably on, in or over the ears of the wearer. This overall arrangement of headphones is known in the art. Also, in some cases a microphone (not shown) can be included so that the headphones can be used as a headset. Further, some headphones or headsets include only one earphone, in which case there may be only one slider.

[0021 ] Cushion assembly 12 is preferably generally tubular. This arrangement allows the sliders to be received within the volume on the inside of the tube and also allows wiring to pass along the length of the cushion assembly. Sliders 14 and 16 are located in part in this interior volume of the cushion assembly.

[0022] Cushion assembly 12 preferably comprises a structural tube 30 that is generally annular and can have a desired cross sectional shape, which in the non-limiting example shown in the drawings is generally rectangular or trapezoidal. However, the shape could be different such as more of a flat oval or the like. The shape is designed to sit comfortably on a head while also providing sufficient interior room and structure to couple with the sliders and allow the sliders to be moved in and out of structural tube 30. Structural tube 30 defines an interior 31. Tube 30 can be made of metal or plastic or other materials.

[0023] Flexible cover 32 is located over at least some of the outside of tube 30 such that the cover defines at least some the outside of the cushion assembly. Cover 32 preferably but not necessarily circumscribes tube 30 and preferably but not necessarily extends the entire length of tube 30. Cover 32 can in part function to cushion the bottom of the tube so that it is more comfortable when worn on the head. Cover 32 also has an aesthetic purpose in that it typically comprises part of or the entirety of the exterior of the cushion assembly that is seen by the wearer and others. Cover 32 needs to be flexible, in part because cushion assembly 12 must be able to flex (bend) along its longitudinal axis so that it can be flexed as it is placed over the head, and also so that it can fit different heads. In some cases the flexion also contributes to pushing the earphones against the head.

[0024] Cover 32 is preferably made at least in part from a fabric or another flexible substrate that stretches in four directions in the plane of the cover, sometimes called four- way stretch fabric. Materials such as neoprene or spandex have this property and can be used but these materials per se are not a limitation. In order for the cover to present a uniform appearance, it is desirable that the cover not fold or bunch as the cushion assembly is bent or twisted. In order to accomplish this objective, the cover should be stretched and held or retained in tension on tube 30. One manner in which a stretchable cover can be held in tension on tube 30 is as follows. Cover 32 can be created as a tube that can be slipped over tube 30. Cover 32 can be longer than tube 30 so that its ends can be folded over the ends of tube 30 and pushed inside of the tube. The ends need to be retained in place so that the cover is held on tube 30 but also is free to move relative to tube 30, while also being held in tension. This retention can be accomplished at least in part by including an adhesive 35 that is located between the interior ends of tube 30 and end 34 of cover 32. See figure 2. Since the adhesive holds the ends of the cover inside of structural tube 30, while the cover is not coupled or connected to the outside of tube 30, the cover is held relatively uniformly in tension and is free to float, or move slightly relative to the outer surface of tube 30. Since the cover can stretch in four directions, as the cushion assembly is flexed and twisted in use the cover remains in tension and thus is less likely to bunch or fold. A result is that the cover maintains a uniform appearance as the headphones are moved, flexed and used.

[0025] End 34 of cover 32 extends over the annular face 36 of tube 30. Retaining member or snap ring 40, figure 3, may be used to help hold the end of the cover in place inside of tube 30 and also present a more finished appearance at the ends of cushion assembly 12. Retaining member 40 is a generally annular snap ring with an annular body 44 that is shaped and sized to closely fit in the inside of the ends of tube 30. Retaining member 40 also includes an enlarged annular face portion 42 that is sized and shaped to overlay face 36 as shown in figures 4-6 and 8.

[0026] Retaining member 40 can be held in place in and against tube 30 by including mating engaging features in the retaining member and on the inside of the cushion assembly, where the features engage one another when ring 44 is properly seated inside of tube 30. These mating engaging features may comprise a detent assembly. The detent assembly may comprise a number of projections that project inwardly from the inside of tube 30 and a number of openings in ring 44 that are each constructed and arranged to receive one of the projections. Other known types of detent assemblies may alternatively be used.

[0027] In the non-limiting example shown in figure 4, tube 30 includes projections 52 and 54 while ring 44 includes two mating openings 46 and 47, figure 4. Opening 46 is shown in more detail in figure 3. Ring 44 can be made from a thin spring steel or the like such that it flexes sufficiently for the ring to be pushed over these projections until the projections pass through and seat in the openings in the ring. Face 42 of ring 44 overlies the face 36 of tube 30 as well as the part of the cover that overlies face 36. A result is that retaining member face 42 provides a more finished appearance of the two ends of the cushion assembly. See figures 5 and 6.

[0028] Tube 30 can be constructed in a desired fashion. For example it can be an extruded plastic or metal tube. Or it can be made in two parts, for example in a clamshell construction that results in longitudinal seams along two opposed sides of the tube. One issue with a clamshell construction is that the outward pressure applied by the snap rings will tend to push the two halves apart. The hoop strength of a tube constructed in this manner can be increased by including a unitary annular member or portion extending from one of the clamshell halves at one or both ends of the tube, as shown in figures 6-8. Alternatively, a separate annular member may be located inside of or outside of the tube. Since these unitary end members do not include a longitudinal central seam that exists in a tube made by a clamshell technique, the end members will help resist the clamshell from being pushed apart.

[0029] One non-limiting example of the construction of cushion assembly 12 is shown in more detail in figures 6-8. Cushion assembly 12 comprises structural tube 30 which is, generally, of a clamshell construction as described above. Tube 30 is made from bottom tube member 60 that is mechanically coupled to top tube member 70. Bottom tube member 60 includes integral hoop or annular member 62 which receives cover retaining member 40. Such a hoop may be located on both ends of tube 30, to support both retaining members. Top member 70 includes lip 71 which underlies the inner portion of member 62 that abuts member 70 at seam 65.

Longitudinal seam 64 where member 70 meets mating portion 61 of member 60 is shown in figure 6. Cover 32 is shown in figure 7 covering tube 30 and engaged behind face 42 of retaining member 40. Cover 32 is smooth in appearance without folds or creases. Slider 16 carries channel member 74 that rotatably carries the headphone yoke (not shown) which carries an earphone (not shown). Cable 72 carries audio signals to the earphones. Cable loops 73 provide slack that allows slider 16 to be moved in and out relative to cushion assembly 12.

[0030] A number of implementations have been described. Nevertheless, it will be understood that additional modifications may be made without departing from the scope of the inventive concepts described herein, and, accordingly, other embodiments are within the scope of the following claims.