SEAMLESS KNIT ENCLOSURE FOR HEADPHONES
20180227657 ยท 2018-08-09
Inventors
- Elizabeth Hilton (Holland, MI, US)
- Brett Harrison Newman (San Francisco, CA, US)
- Kyle Swen (San Carlos, CA, US)
- John O. Mikkola (Commerce Twp., MI, US)
- David Yang (Farmington Hills, MI, US)
- Joshua Brent Poulsen (Salt Lake City, UT, US)
- Sean Missal (San Francisco, CA, US)
Cpc classification
H04R1/02
ELECTRICITY
D10B2403/0333
TEXTILES; PAPER
D04B1/22
TEXTILES; PAPER
International classification
H04R1/10
ELECTRICITY
D04B1/22
TEXTILES; PAPER
Abstract
A seamless knit enclosure for a headphone unit is provided. The seamless knit enclosure may include a pair of earpieces and a headband spanning therebetween. The seamless knit enclosure may include a first region and a second region. The first region may have a stitch construction that has a first elasticity. The second region may have a second stitch construction that has a second elasticity that is different than the first.
Claims
1. A seamless knit enclosure for a headphone unit comprising: a pair of earpieces and a headband spanning therebetween; a first region including a first stitch construction having a first elasticity; and a second region including a second stitch construction having a second elasticity that is different than the first.
2. The seamless knit enclosure of claim 1, wherein the headband defines a longitudinal axis extending between the pair of earpieces and wherein the first elasticity and the second elasticity are measured along the longitudinal axis.
3. The seamless knit enclosure of claim 1, further comprising: a third region defined by each of the earpieces that lies along the second region and defines a third elasticity equal to the first elasticity.
4. The seamless knit enclosure of claim 3, further comprising: a fourth region defined by each of the earpieces including a fourth stitch construction that defines an elongated aperture extending along a length of the enclosure and wherein the fourth stitch construction defines a fourth elasticity that is greater than the third elasticity.
5. The seamless knit enclosure of claim 4, further comprising: a fifth region defined by each of the earpieces, including a fifth stitch construction, that lies along and is in contact with at least one end of the elongated aperture wherein the fifth stitch construction defines a fifth elasticity that is greater than the fourth elasticity.
6. The seamless knit enclosure of claim 1, further comprising: a sixth region defined by the headband including a sixth stitch construction that defines a sixth elasticity that is greater than the first elasticity.
7. The seamless knit enclosure of claim 1, further comprising: a seventh region, defined by a distal end portion of each of the earpieces, including a seventh stitch construction that defines a seventh elasticity that is equal to the second elasticity.
8. A seamless knit enclosure for a headphone assembly comprising: a first earpiece and a second earpiece each configured to receive a speaker of the headphone assembly; and a headband spanning between the first and second earpieces and configured to receive a band of the headphone assembly, wherein the first and second earpieces each define a first region that includes a first stitch construction that defines a first elasticity and headband defines a second region that is comprised of a second stitch construction that defines a second elasticity that is less than the first.
9. The seamless knit enclosure of claim 8, wherein the first stitch construction is arranged in an alternate tuck pattern.
10. The seamless knit enclosure of claim 9, wherein the first stitch construction includes a repeating pattern of a first stitch, a second stitch, a third stitch, and a fourth stitch wherein, the first stitch is arranged to have an upwardly facing crown followed by an upwardly facing peak, the second stitch is arranged to have an upwardly facing peak followed by an upwardly facing crown, the third stitch is arranged to have a downwardly facing crown followed by a downwardly facing peak, and the fourth stitch is arranged to have a downwardly facing peak followed by a downwardly facing crown.
11. The seamless knit enclosure of claim 8, wherein the second stitch construction is arranged in an alternate miss pattern.
12. The seamless knit enclosure of claim 8, wherein each of the earpieces may include a third region, at least partially surrounding the second region, that includes a third stitch construction defining a third elasticity that is equal to the first elasticity.
13. The seamless knit enclosure of claim 12, wherein the third stitch construction includes a plurality of stitches arranged in a visual pattern that is different than a visual pattern defined by the second stitch construction.
14. The seamless knit enclosure of claim 8, further comprising: a fourth region defined by each of the earpieces including a fourth stitch construction that defines an elongated aperture extending along a length of the enclosure and wherein the fourth stitch construction is arranged in a links links pattern.
15. A seamless knit enclosure for a headphone unit comprising: a first earpiece and a second earpiece each configured to enclose a speaker of the headphone unit and each defining a first region that includes a first stitch construction having a first-longitudinal elasticity and a first-transverse elasticity; and an elongated headband extending between the first earpiece and the second earpiece and defining a longitudinal axis wherein the elongated headband defines a second region that includes a second stitch construction having a second-longitudinal elasticity and a second-transverse elasticity that is different than the first-transverse elasticity.
16. The seamless knit enclosure of claim 15, wherein the first stitch construction is comprised of a plurality of stitches arranged in a one-by-one rib construction.
17. The seamless knit enclosure of claim 15, wherein the second-transverse elasticity is measured along a direction that is transverse to the longitudinal axis defined by the headband and wherein second-transverse elasticity is less than the first-transverse elasticity.
18. The seamless knit enclosure of claim 15, wherein the second stitch construction is comprised of a plurality of stitches arranged in an alternate tuck pattern.
19. The seamless knit enclosure of claim 15, further comprising: a third region that includes a third stitch construction having a third-longitudinal elasticity and a third-transverse elasticity that is equal to the third-longitudinal elasticity.
20. The seamless knit enclosure of claim 15, wherein each of the earpieces define an aperture that defines an inner periphery that includes a first yarn and a second yarn arranged in a repeating C-Knitting pattern.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
[0034] As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.
[0035] Headphones generally include multiple plastic pieces that make up an enclosure to cover and protect the electrical and structural components of a pair of headphones. Headphones may include circular or ellipsoid ear pads that encompass or rest against the ears. The ear pads are typically connected to one another by semi-rigid flexible spring-steel band, e.g., headband adapted to be placed on a user's head and wire electrically connecting at least two speakers each disposed adjacent to the ear pads. The use of plastic components often requires a certain thickness to maintain some structure to protect the spring-steel band, wires, and speakers. To fold the headphones, multiple plastic components must be separated to provide sufficient space or a hinge to bend the headphones into a collapsed position. Because plastic is used as the enclosure separate soft ear pads must be provided.
[0036] The disclosure recognizes the above issues and provides an approach to at least partially address it. The present disclosure relates to a seamless knit headphone enclosure and a method of making the same. The enclosure is may comprised of a single piece of fabric having a tubular construction. The headphone enclosure may provide sufficient rigidity in certain locations to maintain and hold the internal components of the headphone assembly together. Other locations are flexible to allow the headphones to be folded into a compact shape. The varying rigidity and flexibility of the enclosure is accomplished by utilizing different stitch constructions offering corresponding elasticity. The headphone enclosure has a one-piece design thereby simplifying the assembly of the headphones. As an alternate embodiment, the headphone enclosure may be used as an accessory and act as an aesthetically pleasing cover for a conventional headphone assembly.
[0037] A seamless knit structure is often produced by what is referred to as a complete garment knitting process or three-dimensional (3D) knitting. As opposed to conventional knitting, that requires shaped pieces to be sewn together, 3D knitting machines utilize computerized instructions that direct movement of several needs to construct and connect several tubular knitted forms to create a complete garment in a single step. 3D knitting decreases wasted materials and eliminates several steps associated with conventional sewing.
[0038] 3D knitting may be accomplished by various techniques, including but not limited to flat knitting, warp knitting, weft knitting and circular knitting. In one embodiment, the seamless headphone enclosure is may be produced by flat bed weft knitting. Flat bed weft knitting is a method that creates a knitted fabric by moving a number of feeders or vessels that carry the thread across a needle bed. As the needles within the needle bed move up and down to engage the thread, a loop is created. As multiple loops are created, the knitted structure is developed.
[0039] The amount of material generated is measured by wales per inch (WPI). The amount of WPI is dependent on the number of needles required to create an inch width of fabric. As one example, if a piece of fabric has a 50 WPI then 50 needles are required to create one inch. Another unit of measure related to knitted structure is course per inch (CPI). CPI refers to how many knitting rows required to create one inch of a knitted part. As one example, if a piece of fabric has a 100 CPI, then 100 knitting rows are required to complete one inch of knitting.
[0040] In one embodiment, flat bed differs from warp knitting, circular knitting, or weaving. Flat bed knitting facilitates the creation of more versatile, complex, and unique products with various materials in isolated areas. Conventional flat bed weft knitting typically has only two needle beds. The process used to create the headphone enclosure may have four needle beds. A variety of yarns may be utilized to create the headphone enclosure of one or more embodiments. In one embodiment, one feeder provides a double covered elastic yarn that has an elastane core covered in nylon. The other yarn may have a composition that is 83% nylon and 17% spandex by weight. In other embodiments the composition may include one of or a range of the following percentage of nylon, with the balance being spandex: 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, by weight. In other embodiments the composition yarn may include a percentage of steel or carbon fiber by weight with the balance being either nylon or spandex.
[0041] In the following discussion of the figures, a polar coordinate system is utilized. A longitudinal axis extends along the headband between the earpieces of the headphone enclosure. A transverse axis extends orthogonal to the longitudinal axis.
[0042] The headphone enclosure may include at least seven regions, each comprising a stitch construction that is unique to each region. Each stitch construction provides a unique elasticity. Elasticity may refer to the ability of the region to resist distortion or deforming and its ability to retain or return to its original size and shape. Elasticity may be measured along the longitudinal or the transverse axis, or both. Mechanical strain is integrally related to elasticity. While elasticity refers to the property of solid material to return to its original shape and size after the force deforming it has been removed, strain refers to a change in some spatial dimension, e.g., length, angle or volume, compared to its original value.
[0043] Mechanical properties of a weft knitted structure may vary depending on the type of stitch or stitch construction utilized. The strain of a knitted structure refers to the percentage change in length in response to a constant force. A knit structure having a low strain rate or low elasticity may have a range between 1% and 11%. A knit structure having a medium strain rate or medium elasticity structure may have a range between 11% and 14%. A knit structure having a high strain rate or high elasticity may have a range between 14 and 20%.
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[0045] Referring to
[0046] Referring to
[0047] A pair of second regions 24 make up a portion of the headband 30 that extend to the earpieces 34 36. The two second regions 24 are each comprised of an alternate miss pattern that only knits on every fourth needle. This thread structure provides a low elasticity as along the transverse axis and a medium elasticity along the longitudinal axis.
[0048] A third region 18 is disposed between the first region 16 and a portion of the outer periphery of each earpiece that extends along the direction of the longitudinal axis. Like the first regions 16, the third region 18 is comprised of an alternate tuck thread structure. As mentioned above, the alternate tuck thread structure provides a medium elasticity along the longitudinal and transverse axes. Despite having the same thread structure as the first region 16, the aesthetic pattern of the third region 18 differs from the first region in that it is a series of cross-hatched lines.
[0049] Each earpiece includes an aperture 38 that is sized to accommodate the insertion of a headphone assembly (not pictured). A fourth region 20 extends around the periphery of the aperture 38. The fourth region 20 is comprised of a links links stitch construction. The links links stitch construction provides maximum elasticity along the longitudinal and transverse axes. The maximum elasticity of the stitch construction facilitates the insertion of the headphones. Peripheral stitching 23 surrounding the aperture 38 is comprised of a thread structure made from C-Knitting. The peripheral stitching 23 will be explained in greater detail below.
[0050] A fifth region 22 is disposed between the first region and the fourth region. The fifth region 22 is comprised of a one by one rib stitch construction. Similar to the fourth region 20, the fifth region 22 provides maximum elasticity along the longitudinal and transverse axis. Again, the maximum elasticity of the stitch construction facilitates the insertion of the head phones.
[0051] The headband 30 may include a sixth region 26 and two second regions 24 disposed on either side of the sixth region 26. The sixth region 26 may have a black and white dotted pattern and the two second regions 24 have a black and white striped pattern that extend parallel to the longitudinal axis. The sixth region is comprised of an alternate tuck thread structure. The alternate tuck thread structure provides a medium elasticity along the longitudinal and transverse axes.
[0052] A seventh region 12 is disposed between the fifth region 22 and a portion of the outer periphery that is transverse to the longitudinal axis. The seventh region 12 has an aesthetic pattern of a series of alternating black and white lines that are substantially aligned parallel with the longitudinal axis. The seventh region is comprised of an alternate miss stitch construction. The alternate miss stitch construction provides a low elasticity along the transverse axis.
[0053] As mentioned above, a number of transitions are provided between the regions. A first transition 40 is provided between the second region 24 and the sixth region 26. The first transition 40 is used to create a half-gauge twill pattern that is consistent with the width and the drop required to fit the enclosure 10 on the headphone band. A second transition 42 is provided between the second region 24 and the fifth region 22. The second transition 42 facilitates the change between a full gauge construction to a half gauge construction. A third transition, is used throughout the seventh region 12. A fourth transition 44, forms the start, indicated by s, and the end, indicated by e of the headphone enclosure 10. The fourth transition 44 as further shown in
[0054] Referring
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[0065] While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.