Headband and method of manufacturing the same

Abstract

The present disclosure relates to a headband and a method of manufacturing the headband. A headband for a headset and a method of manufacturing the headband for a headset are disclosed. The headband is configured to carry at least one ear cup of the headset. The headband includes a bracket and a rubber suspension formed by overmolding. The method includes the steps of providing a bracket, arranging the bracket in an injection molding tool, and forming the suspension from a rubber material by overmolding so that the suspension forms at least two attachment points to the bracket.

Description

Technical Field

[0001] The present invention relates to a headband for headphones and a method for manufacturing the headband. The headband includes a bracket and a rubber suspension formed by overmolding. Background Art

[0002] Headsets may be used in a variety of settings, and users may wear the headsets for a long span of time. Headset users require a comfortable design, good fit, and stability from the headset. In addition, most users prefer lightweight and discrete headsets. Therefore, there is a need for a headset that has a good overall fit to the user's head while providing good comfort to the user. All of these characteristics depend primarily on the headband that is typically worn on the user's head. There are many different headbands on the market. Most of the available headbands have multiple parts that allow the user to adjust the headband to their preferences. Headbands with many separate parts can be complicated to use, moving parts are prone to wear, the user may not be able to achieve the best fit, and the assembly of such headbands can be complicated and therefore expensive.

[0003] There is a need for an improved method of manufacturing a headband, and a headband for a headset that overcomes the problems of the prior art. Summary of the invention

[0004] It is an object of embodiments of the present invention to provide an integrated headband that fits all head sizes.

[0005] It is a further object of embodiments of the present invention to provide a headband having a simplified design compared to headbands known in the prior art.

[0006] It is another object of embodiments of the present invention to provide a headband that is easy to manufacture.

[0007] It is another object of embodiments of the present invention to provide a lightweight headband, thereby providing great comfort to potential users.

[0008] In a first aspect, the present invention discloses a method of manufacturing a headband for a headset. The headband includes a bracket and a suspension. The headband is configured to carry at least one ear cup of the headset. The method includes the steps of providing the bracket and arranging the bracket in an injection molding tool. The method also includes the steps of forming the suspension by overmolding a rubber material so that the suspension forms at least two attachment points to the bracket at a first suspension end and a second suspension end. The suspension forms a head pad extending between the first suspension end and the second suspension end.

[0009] In this document, the term "headband" is interpreted as referring to a band to be worn on a user's head, and in particular a band worn on a user's head when the ends of the headband may abut the sides of the user's head, such as at the ears. In the following, the terms "user" and "wearer" may be used interchangeably with respect to a person wearing the headset on his / her head.

[0010] The headband is suitable for headphones, and in particular headphones that are worn over the head. In other words, the headband forms part of the headphones. In addition to the headband, the headphones also include ear cups carried by the headband. The engagement between the headband and the ear cups can be established in various ways known in the art. The ear cups are usually arranged at one end of the headband. The other end of the headband can include a stabilizing element adjacent to the side of the user's head to ensure the correct positioning of the headband and the headphones. The ear cups define an inner surface, which is usually used to engage with one ear of the user. The ear cups may include various electronic components necessary for the normal operation of the headphones, and in particular a speaker configured to generate sound signals. Optionally, the ear cups may be passive mechanical devices configured to provide noise attenuation / cancellation. The headphones may also include a microphone and / or another ear cup arranged on the other ear of the user. The microphone may be arranged on the ear cup, or directly on the headband. The microphone may be arranged on a microphone boom.

[0011] The headband of the present invention may be used in audio headphones, ie headphones used for audio purposes, and / or it may be used in noise attenuating headphones providing passive noise attenuation capabilities.

[0012] The headband comprises a support and a suspension. The support and the suspension may form one part. That is, the support and the suspension may form an integral component and cannot be separated from each other in a non-destructive manner (ie without damaging the headband).

[0013] When manufacturing a headband, first, a bracket is provided. The bracket can generally be U-shaped with two ends and can exhibit flexibility to ensure fit for various head sizes, particularly various head widths of potential users. The bracket can be made of a metal material, a plastic material, or even wood. The bracket can be machined, molded, or even handmade. Regardless of the material selection, the thickness and width of the bracket can provide good mechanical stability and flexibility at the same time. In addition, the bracket can be configured to provide a basic clamping force applied to the user's head. The basic clamping force is controlled by controlling the thickness and cross-section of the bracket. The provided bracket can be manufactured so that it has very small changes and deviations from the modeled bracket.

[0014] Once provided, the bracket is arranged in an injection molding tool. The injection molding tool may include a mold for molding the suspension to form the headband. The mold may form a bracket cavity for placing the bracket and a suspension cavity for forming the suspension. The bracket cavity may include at least two sub-cavities, a lower forming portion and an upper forming portion, a forming portion for forming a connection between the suspension and the bracket. The sub-cavity can also be regarded as a part of the suspension cavity.

[0015] The injection molding tool may define a lower forming portion configured to accommodate a bracket of the headband. The tool may also include an insert and an upper forming portion. The insert may define attachment points and pads and may be replaced with another insert so that different embodiments of the headband can be realized. That is, the insert may define the distance between the attachment points, the thickness of the pads, and the spacing between the bracket and the pads. The insert may also define whether the bracket is completely overmolded between the attachment points or only overmolded at the attachment points. The insert may define a suspension with pads, and wherein the bracket is completely encapsulated by the rubber material between the attachment points. Sharing a common lower forming portion and an upper forming portion, and having interchangeable inserts, minimizes the required tool manufacturing, thereby reducing tool costs. Once the bracket is set in the tool, the rubber material can be injected into the mold under high pressure to form the suspension. Once the rubber material is cured, the tool can be opened and the headband can be removed from the tool.

[0016] The suspension is generally configured to be placed on top of the user's head and abut against the head when the headband is in use, thereby at least partially supporting the weight of the entire headset. The suspension can assist in the basic clamping force generated by the bracket to fine-tune it, especially when the headband is installed in the appropriate position on the head. The suspension defines a headband pad, which can provide a firm headband fit and further ensure good wearing comfort, especially thanks to its soft and easily stressed and deformed rubber material, which can ensure long-term wearing comfort. By carefully selecting the rubber material for the suspension and pad, the wearing comfort can be greatly improved. Generally, soft rubbers are selected for overmolding. Soft rubbers generally have good processing characteristics because they are widely used in various applications. Therefore, the manufacture of the headband is simplified. Since the suspension is made of rubber material, when the user stretches the headband to fit it to the head, the suspension will automatically adjust to fit the head and ensure good fit and comfort. The soft rubber material also allows for a relatively small thickness of the pad, for example anywhere between 2mm and 10mm, thereby providing a headband that is not bulky and therefore does not affect the design, appearance and / or weight of the headset. However, in some embodiments, where the bulk of the headband is not required, the pad may be thicker than 10mm, for example 20mm, or even 30mm, or any thickness between 10mm and 30mm. Any of natural rubber, silicone rubber, polyurethane or the like may be used in the overmolding process to form the suspension. Thanks to the soft rubber used for the suspension, the headband can be easily removed from the injection molding tool. The rubber material used for the suspension can be easily colored / colored so that it has the same color as the bracket. The density of the rubber material used for the suspension can be around 1mg / mm 3 Up to 1.3 mg / mm 3 The hardness is in the range of 30 to 80 Shore A, the tensile strength is between 6 MPa and 11 MPa, the elongation at break is between 300% and 660%, the right-angle tear strength is between 20 kN / m and 32 kN / m, the resilience is between 50% and 70%, and the compression set is between 8% and 15% at 180°C.

[0017] According to the present invention, a headband is formed by overmolding a rubber material onto a bracket, which in this context forms a substrate for overmolding. The steps of overmolding are: an injection molding process, during which the rubber material is in a liquid state and is injected into an injection molding tool under high pressure and coats the substrate at two attachment points, forming a pad at the same time. After the rubber hardens, the bracket and the suspension are permanently joined together as a single component and the entire structure can be removed from the molding tool. Before overmolding, a layer of an agent can be applied to the bracket to increase the bonding force between the bracket material and the rubber material. The bracket provides the desired stiffness to the headband, while the suspension provides comfort to the user. An advantage of the present invention is that the suspension is formed by overmolding a rubber material, because the rubber material is easy to mold and because the rubber material is highly deformable.

[0018] Prior to overmolding, the rubber material is mixed with various additives such as colorants, foaming agents or other fillers to achieve a mixture that will produce a suspension with a specific color and / or hardness.

[0019] The suspension forms at least two attachment points to the bracket at the first suspension end and the second suspension end. The two attachment points can be arranged at a distance equidistantly spaced from the midpoint of the bracket. The midpoint is usually equidistant from both ends of the U-shaped bracket. The attachment points can be arranged at 1 cm to 10 cm, for example, at a distance of 5 cm to 10 cm from the midpoint of the bracket. The attachment points can be defined according to the needs of the user. Each attachment point can be defined by its width, which can range from only a few millimeters to up to 5 centimeters. By arranging the attachment points symmetrically around the midpoint of the bracket, the stability of the headband arranged on the user's head can be improved. In addition to the first suspension end and the second suspension end formed at the attachment point, the suspension also includes a head pad extending between the first suspension end and the second suspension end. When the first end and the second end are naturally formed of the same rubber material, the pad is also formed by overmolding at the same time and in the same processing steps.

[0020] In order to form a suspension that is attached to the bracket at only two attachment points, the injection molding tool may include a very narrow cavity designed to accommodate only the bracket. That is, the cavity for accommodating the bracket can be narrow so that no rubber material can float out of the two small cavities to form the attachment points. Alternatively or additionally, the bracket can be covered so that no rubber material can cover the bracket except at the attachment points. The suspension, including the points of attachment to the bracket, is overmolded. Therefore, in the broadest range, only the two points of the bracket to which the suspension is attached will be overmolded.

[0021] A headband made of rubber is provided to be overmolded to fit a one-piece headband of all head sizes. Such a headband provides a simplified design compared to most headbands known in the art. A uniformly sized headband is a user-friendly design because it does not require the user to adjust the size of the headband to ensure a good fit. The headband according to the present invention is easy to manufacture because it only requires two different materials and a few steps of making a bracket and then arranging the bracket in a tool for overmolding. Such simple manufacturing saves manufacturing time because no other assembly steps in the production line are required. By carefully designing and selecting the bracket, the present invention provides a lightweight headband with a soft pad, thereby providing great comfort to potential users. At the same time, an elegant design that is generally desired by most users is achieved. In addition, the headband according to the present invention provides a uniform clamping force that is evenly distributed on the user's ears and head by the bracket and suspension design. Therefore, the headband is easy to use because the user does not need to adjust the tightness of the headband all the time. In addition, the high pressure of the injection molding ensures that the rubber material reaches even the smallest gap of the mold, thereby achieving a precise geometry through overmolding, thereby producing a headband according to a predefined form. Finally, including the suspension pad as part of the headband provides a headband wherein pressure on the user's head is evenly distributed along the contact between the user's head and the headband.

[0022] In some embodiments, overmolding the rubber material around the bracket is performed in one processing step. That is, after the bracket is arranged in the injection molding tool, the liquid rubber material is immediately injected into the inlet of the mold under controlled high pressure. The high pressure pushes the liquid rubber material forward so that the cavity filled with the rubber material is completely filled to form the suspension. The molding tool may have one or more gates representing the inlet of the rubber material into the tool. The rubber material can be injected into all inlets at the same time. Injecting the rubber material into the molding tool in one processing step ensures that the suspension is uniformly cured, that is, each part of the suspension will have the same curing time. Moreover, overmolding in only one step greatly reduces the manufacturing complexity of the headband. During the overmolding process, bonding occurs between the bracket material and the rubber material because, when filling the cavity of the mold, the liquid rubber material impregnates the top layer of the bracket to the extent that the particles of the bracket and the rubber are mechanically fixed after the rubber is cured, thereby forming an integral one-piece headband. After curing is completed, the molding tool is opened and the headband pops up or can be removed manually.

[0023] In some embodiments, the method for manufacturing a headband may further include the step of molding at least one telescopic extension for the headband. The telescopic extension may be formed by injection molding. The telescopic extension may be manufactured separately from the overmolded bracket. The telescopic extension may extend longitudinally and have a generally circular cross-section. The telescopic extension may have a longitudinal hole configured to accommodate one end of the bracket. The hole may extend through the entire telescopic extension, or may extend through only a portion of the telescopic extension, such as one-third of the length. The telescopic extension may be a sleeve-like unit configured to slide over the bracket. The telescopic extension provides additional adjustability to the headband, thereby providing better comfort for different head sizes, lengths, and widths, as the telescopic extension may also help if the user has a wide head.

[0024] In some embodiments, the method for manufacturing a headband for headphones may further include the step of assembling at least one telescopic extension to the headband. The sleeve-shaped extension may be movably arranged on one arm of the U-shaped bracket. The extension may be movable along the arm of the U-shaped bracket. The ear cup may be arranged on the extension. The bracket may have extensions arranged on both arms of the U-shaped bracket.

[0025] In some embodiments, overmolding the rubber material around the bracket may include overmolding the rubber material around the bracket to form two attachment points and providing a head pad spaced from the bracket. The operation of providing the attachment point and the head pad between them may be performed in one injection molding step. The rubber material may wrap the bracket at the attachment point, and the attachment point may gradually become a pad. When the headband / headphones are worn in their intended position, the head pad may be configured to be placed above the wearer's head, and the portion of the bracket between the two attachment points is configured to hover above the head pad and the wearer's head. When the headband is not used, the gap formed between the pad and the bracket may exist. When the headband is used, the pad may be closer to the bracket because it may be pushed by the user's head, so that there is no gap. Spacing the pad and the bracket apart provides additional comfort for the user. The gap may range between a few millimeters and two centimeters. Alternatively, the pad may abut the bracket even if the headband is not used. Thanks to the soft rubber used for the suspension, the headband in this embodiment will also provide comfort to the user. In this embodiment, the thickness of the pad may be slightly greater than the thickness of the pad spaced apart from the support.

[0026] In some embodiments, the suspension can be overmolded around at least a portion of the support to completely encapsulate that portion of the support. That is, the attachment point and the pad may not be separated, but the rubber material can be wrapped around a portion of the support, particularly the portion that is configured to hover above the user's head. Alternatively, the entire support can be encapsulated in the rubber material. In yet another alternative, the rubber material can be overmolded only on the bottom side of the support, that is, the side facing the user's head when the headband is in the intended position on the user's head. In all of these embodiments, a pad can be produced, that is, there may be a portion of the rubber material that is thicker than the rest. When the headband is in use, this portion will be placed around the top of the user's head. Overmolding the rubber material around the support forms a more robust structure that will not delaminate, as delamination typically occurs in many other headbands in the art.

[0027] In a second aspect, a headband for headphones manufactured by the above method is disclosed. It should be understood that all embodiments, benefits and advantages described in conjunction with the first aspect are equally important for this second aspect.

[0028] In a third aspect of the invention, a headband for a headset is disclosed, the headband being configured to carry at least one ear cup of the headset. The headband comprises a support and a suspension. The support is curved to substantially conform to any wearer's head. The suspension is formed of a rubber material by overmolding. The suspension is attached to the support at at least two attachment points. The suspension forms a head cushion. The support may be elastically deformed to conform to the user's head and ears. It should be understood that all embodiments, benefits and advantages described in conjunction with the first aspect are equally important to this third aspect.

[0029] The bracket can be made of metal, hard plastic and wood. Specifically, a metal bracket with over-molded rubber provides a headband that can be stretched to fit human head sizes of different widths. The headband can generally extend in the x-direction, that is, parallel to the line connecting the user's ears, such as the ear-to-ear (E2E) direction across the head. The soft rubber pad can automatically adapt to the person's head and can be deformed vertically, thereby providing good wearing comfort and a secure fit.

[0030] In some embodiments, the bracket and the suspension can contribute to the clamping force of the headband. The clamping force is related to the tightness of the headband. The clamping force is also related to the amount of pressure applied by the headband to the user's head. The clamping force ensures a good overall fit and engagement of the headband and ensures a tight fit of the corresponding headset. The bracket can provide the main clamping force, while the suspension can play a role by fine-tuning the main clamping force. The basic clamping force can be evenly distributed along the bracket. The clamping force can also be evenly distributed along the headband. Mainly due to the evenly distributed clamping force, the headband according to the present invention can be adapted to all adult user head sizes. However, the ratchet length of the bracket can be adjusted, thereby changing the length of the bracket. By adjusting the ratchet length, different opening distances of the headband can be achieved, thereby obtaining different clamping forces. A longer flexible length will fit a wider head, thereby achieving an appropriate clamping force level. In some embodiments, it is expected that only the bracket contributes to the clamping force. Generally, the more complex the suspension design is, and the more rubber material is overmolded on the bracket, the more the clamping force depends on the suspension in addition to the basic bracket clamping force. By placing the rubber material only on the outer surface of the support and taking into account that the elongation of rubber is very high, so that the rubber material can follow the deformation of the support, the influence of the suspension on the total clamping force can be reduced. In the solutions known in the prior art, multiple separate parts contribute to the clamping force of the headband, resulting in uneven clamping force.

[0031] In some embodiments, the suspension may include a first rubber material portion and a second rubber material portion. The first rubber material portion may form an attachment point. The second rubber material portion may be spaced apart from the first rubber material portion. When the headband / headphones are worn in the desired position on the user's head, the second rubber material portion may be configured to be placed above the wearer's head. When the headband / headphones are worn in the desired position on the user's head, the first rubber material portion may be configured to hover above the second rubber material portion and the wearer's head. The first rubber material portion may be formed only between the attachment points and on the top side of the bracket. Alternatively, the first rubber material portion may be formed only between the attachment points surrounding the bracket and on the bottom side of the bracket facing the second rubber material portion. In yet another alternative, the first rubber material portion may encapsulate a portion of the bracket between the two attachment points. The second rubber material portion may form a pad for the headband. The suspension with pads provides excellent wearing comfort, especially for long-term use. Such a headband may provide a soft pad with a thickness of only 2mm to 10mm, thereby providing a comfortable and lightweight headband that looks slim and neat. This design provides many improvements over traditional bulky designs which often result in bulky headbands.

[0032] In some embodiments, the headband may further include at least one telescopic extension slidably disposed on one end of the headband. The telescopic extension is disposed on the headband to allow the headband to be adjusted to accommodate different head sizes in width and length. The telescopic extension may additionally contribute to the clamping force of the entire headband. The ear cups may be disposed on the telescopic extension. Thus, the telescopic extension allows the user to properly position the ear cups relative to the user's ears. The telescopic extension may define a pivot portion on which a microphone may be disposed.

[0033] In some embodiments, at least one telescopic extension may be arranged on the headband by a hook. Alternatively, a spring may be provided to secure the telescopic extension to the metal / rubber. The telescopic extension may also be arranged to the bracket in a manner that fits the groove by providing a groove in the bracket and a corresponding protrusion on the extension. The extension may be arranged on the bracket by a snap fit. The telescopic extension may be removably arranged on the headband. The user may be able to manipulate it so as to achieve the best possible fit of the headband depending on the current use. The user may also remove the extension in case he / she does not need it.

[0034] The second rubber material portion may have a concave cross-sectional shape facing the first rubber material portion. The concave shape of the pad towards the support allows for a reduction in the material used for the pad. In addition, this shape improves the flexibility and deformability of the pad. The concave shape will also provide strength to the suspension itself, as such a bridge-like shape is less susceptible to gravity. The cross-section of the surface of the second rubber material portion pointing toward the user's head may be convex. The convex shape improves wearing comfort, as there are no sharp edges to cause discomfort. Likewise, the convex shape ensures that the pressure applied by the headband to the wearer's head is evenly distributed over the entire surface of the pad.

[0035] In some embodiments, the headband for headphones may also include an earphone unit and a cable attached to the bracket, the cable being configured to electrically connect the earphone unit and the ear cup. The earphone unit may include a microphone. The unit may be arranged on the same side of the headband as the ear cup. Otherwise, the unit may be arranged at the other end of the headband and may be arranged together with another ear cup. The cable may also electrically connect the two ear cups arranged at both ends of the headband, thereby forming a stereo headset. The cable may be attached to the bracket before the step of forming the suspension by overmolding. The cable may be attached to the bracket by adhesive. Alternatively, a pin or the like may be used to attach the cable to the bracket. When the rubber material is overmolded to form the suspension, the portion formed around the attachment point may additionally secure the cable to the bracket. Alternatively, the rubber material may be overmolded over a larger portion of the bracket, for example to form a continuous structure from one attachment point to another attachment point, thereby enclosing the cable between the bracket and the rubber overmolded on a portion of the bracket. In yet another alternative, the rubber material can completely encapsulate the cable so that the cable is not visible on the final headband. When the user wears the headband, the cable can be arranged on the inside of the bracket, facing the user's head, or can be arranged on the outside of the bracket, away from the user's head.

[0036] The bracket can be a metal bracket. Any metal can be used as the bracket, such as aluminum, copper, iron, tin, gold, lead, silver, titanium, zinc, etc. In addition, metal alloys such as steel can also be used. The bracket can be a cold-rolled stainless steel strip. The metal bracket can be formed into a curved shape, such as a U-shape. The metal U-shaped bracket can be flexible. With a metal bracket, sufficient rigidity and sturdiness are provided to the headband, and since metal processing is already well performed, the bracket can be appropriately designed and shaped to exhibit the desired clamping force. In addition, the metal is suitable for overmolding with rubber materials.

[0037] The bracket can also be cast from any hard plastic that can be bent and can be flexible. A plastic bracket can be formed by injection molding using one mold, and then the substrate can be formed by overmolding in another injection molding tool. Thermoplastics that soften and can be formed by heating can be used. Thermoplastic brackets can be formed by injection molding, blow molding or vacuum forming. Examples of thermoplastics are acrylic, polypropylene, polystyrene, polyethylene and PVC. The bracket can also be made of thermosets, such as melamine, bakelite, polyester and epoxy resins formed by thermal processes.

[0038] The bracket can also be made of a composite material made by mixing materials together to obtain enhanced properties. Polyester resin can be mixed with glass fiber, and epoxy resin can be mixed with carbon fiber to obtain a bracket that is stronger than steel but lighter.

[0039] Brackets may also be made from acrylic, PVC and uPVC, polyethylene, high density polyethylene (HDPE), and tough yet flexible low density grades of polyethylene (LDPE).

[0040] The stent may be provided in the form of a curved strip. The thickness of the stent may be in the range between 0.5 mm and 5 mm. The width of the stent may be in the range between 1 cm and 3 cm. The total length of the stent may be in the range between 10 cm and 30 cm. The yield strength of the stent may be in the range between 500 MPa and 1000 MPa. The tensile strength of the stent may be in the range between 1000 MPa and 1500 MPa. The hardness of the stent may be in the range between 400 HV and 500 HV.

[0041] In a preferred embodiment, the bracket is made of metal, and the suspension is made of silicone rubber. In other embodiments, the bracket can be made of a hard plastic such as LDPE, and the suspension can be made of a soft rubber such as silicone rubber.

[0042] The present invention relates to different aspects, including a method for manufacturing a headband described above and below, and a corresponding headband manufactured by the method, and a headband, each of which produces one or more advantages and benefits described in combination with the first aspect, and each has one or more embodiments corresponding to the embodiments described in combination with the first mentioned aspect and / or disclosed in the attached claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0043] The above and other features and advantages will become apparent to those skilled in the art from the following detailed description of exemplary embodiments with reference to the accompanying drawings, in which:

[0044] Figure 1 An exemplary embodiment of a method for manufacturing a headband for headphones according to the present invention is shown,

[0045] Figure 2 Schematically illustrating the formation of an injection molding tool and a headband according to an embodiment of the present invention,

[0046] Figure 3 schematically illustrates an exemplary embodiment of a headband for headphones according to the present invention,

[0047] Figure 4 Schematically showing another exemplary embodiment of a headband for headphones according to the present invention,

[0048] Figure 5 schematically shows a further exemplary embodiment of a headband for headphones according to the present invention, and

[0049] Figure 6A headset with a headband according to an embodiment of the present invention is schematically shown. DETAILED DESCRIPTION

[0050] Various embodiments are described below with reference to the accompanying drawings. Throughout the text, the same reference numerals represent the same elements. Therefore, the same elements will not be described in detail with respect to the description of each figure. It should also be noted that the drawings are intended only to facilitate the description of the embodiments. They are not intended to be an exhaustive description of the claimed invention or a limitation on the scope of the claimed invention. In addition, the illustrated embodiments do not necessarily have all the aspects or advantages shown. The aspects or advantages described in conjunction with a particular embodiment are not necessarily limited to that embodiment, and may be practiced in any other embodiment even if not so shown or so explicitly described.

[0051] Throughout, the same reference numerals are used for the same or corresponding parts.

[0052] Figure 1 An exemplary embodiment of a method 100 for manufacturing a headband for headphones according to the present invention is shown. The headband includes a carrier and a suspension. The headband is configured to carry at least one ear cup of the headphones. The method 100 for manufacturing a headband for headphones includes step 102 of providing a carrier. Then, the method includes step 104 of arranging the carrier in an injection molding tool. Finally, the method includes step 106 of forming the suspension by overmolding, during which at least two attachment points and a head pad are generated between the suspension and the carrier. The suspension is formed of a rubber material. The attachment points are formed at a first suspension end and a second suspension end. The head pad extends between the first suspension end and the second suspension end.

[0053] Figure 2 (a) and Figure 2 (b) schematically illustrates the formation of an injection molding tool 200 and a headband according to an embodiment of the present invention in a compact view (a) and an exploded view (b). The injection molding tool 200 defines a lower forming portion 202 configured to accommodate a bracket of the headband. The tool also includes an insert 204 and an upper forming portion 206. The insert 204 can define attachment points and pads, and can be replaced with another insert, so that different embodiments of the headband can be achieved. That is, the insert 204 can define the distance between the attachment points, the thickness of the pad, and the spacing between the bracket 302 and the head pad 310. The insert 204 can also define whether the bracket is completely overmolded between the attachment points or only overmolded at the attachment points. Figure 2The insert 204 shown in FIG. 1 defines a suspension having a head cushion 310 and wherein the bracket 302 is completely encapsulated by the rubber material between the attachment points. Sharing a common lower forming portion 202 and upper forming portion 206 and having interchangeable inserts minimizes the tooling required, thereby reducing tooling costs. Once the bracket 302 is provided in the tool, the rubber material is injected into the mold under high pressure to form the suspension. Once the rubber material cures, the tool 200 can be opened and the headband 300 can be removed from the tool 200. In FIG. 1 , an exploded view is shown. Figure 2 In (b) the separated pieces of the forming tool 200 can be seen, as well as the headband 300 according to one of the embodiments of the present invention.

[0054] Figure 3 An exemplary embodiment of a headband 300 for headphones according to the present invention is schematically shown. The headband 300 for headphones is configured to carry at least one ear cup (not shown) of the headphones. The headband 300 includes a bracket 302 that is curved to adapt to any wearer's head. It also includes a suspension 304. The suspension 304 is formed of a rubber material by overmolding. The suspension 304 is attached to the bracket 302 at at least two attachment points 306 and 308. The suspension 304 forms a head pad 310. The bracket 302 can be U-shaped.

[0055] Figure 4 (a) and Figure 4 (b) schematically shows another exemplary embodiment of a headband 300 for headphones according to the present invention. The headband 300 is shown in a compact view (a) and an exploded view (b). According to this embodiment, the headband includes a bracket 302, and a cable 312 is attached to the bracket 302. The cable 312 is configured to electrically connect ear cups (not shown) that can be arranged on both ends of the bracket 302, thereby producing a stereo headset. The cable 312 can also be configured to connect the earphone unit and the ear cups (not shown) arranged on the ends of the bracket 302. The cable 312 can be attached to the bracket 302 before the step of forming the suspension 304 by overmolding. The cable 312 can be attached to the bracket 302 by adhesive. When the rubber material is overmolded to form the suspension 304, the portion formed around the attachment points 306 and 308 can additionally fix the cable to the bracket. Figure 4The illustrated embodiment discloses a rubber material overmolded over a larger portion of the bracket 302, thereby forming a continuous structure from one attachment point 306 to another attachment point 308, which encloses the cable between the bracket 302 and the rubber overmolded over a portion of the bracket, and secures the cable 312 within the bracket 302 extending from the attachment point 306 to one end 314 of the bracket 302 and from the attachment point 308 to the other end 316 of the bracket 302. In this embodiment, the rubber material completely encapsulates the cable, making it invisible on the finished headset because Figure 4 The end visible on (a) will be connected to the ear cup / headphone unit / microphone. In this embodiment, the cable 312 is arranged on the inside of the bracket, facing the user's head. In an alternative embodiment, when the user wears the headband, the cable 312 can be arranged on the outside of the bracket 302, away from the user's ears.

[0056] according to Figure 4 In the illustrated embodiment, the head pad 310 has a concave shape in a cross section facing the support 302, in particular, a portion of the head pad 310 that is facing the support 302 and that is suspended above the head pad 310. The concave shape of the pad facing the support allows for a reduction in the material used for the pad, improving the flexibility and deformability of the pad 310. The opposite side of the head pad 310 that faces the user's head (when the headband is placed over the user's head) is convex. The convex shape improves wearing comfort because the pressure exerted by the headband 300 on the wearer's head is evenly distributed over the surface of the head pad 310. The head pad 310 can be more comfortable than Figure 4 The embodiment shown is longer or shorter. The length of the pad is determined by the spacing between the attachment point 306 and the attachment point 308. This spacing can be controlled by using different inserts in the insert molding tool.

[0057] Figure 5 Another exemplary embodiment of a headband 300 for headphones according to the present invention is schematically shown. Figure 4 In addition to the features described, the headband 300 also includes two telescoping extensions 318 and 320 disposed on the two ends 314 and 316 of the bracket. The telescoping extensions may be formed by injection molding and may be manufactured separately from the overmolded bracket. Figure 5 The telescopic extensions 318 and 320 shown are sleeve-like units configured to slide on the bracket. The telescopic extensions 318 and 320 provide additional adjustability to the headband so that it can provide better comfort for different head sizes, lengths and widths because the extensions can be movably arranged on the arms of the U-shaped bracket. The ear cups, headphone units and / or microphones can be arranged on the extensions 318, 320. In some other embodiments, the bracket may have only one extension arranged on one arm of the U-shaped bracket.

[0058] Figure 6 The earphone 400 with the headband 300 according to an embodiment of the present invention is schematically shown. The earphone 400 includes a headband 300 and a headband 300. Figure 4 and Figure 5 The headband 300 is described. The headband 300 is defined by a bracket 302 overmolded with a rubber material that defines a head cushion 310. The headband of this embodiment also includes telescopic extensions 318, 320, and ear cups 322 and 324 are arranged on the telescopic extensions 318, 320. One ear cup 324 has a boom microphone 326 arranged thereon. Those skilled in the art will understand that various combinations of ear cups, microphones, and telescopic extensions can be used. In addition, another form of suspension 304 can also be used Figure 6 The earphone 400 shown in FIG. Figure 3 Suspension shown.

[0059] Although specific features have been shown and described, it should be understood that they are not intended to limit the claimed invention, and it will be apparent to those skilled in the art that various changes and modifications may be made without departing from the scope of the claimed invention. Accordingly, the description and drawings should be regarded as illustrative rather than restrictive. The claimed invention is intended to cover all alternatives, modifications and equivalents.

[0060] Reference Mark List

[0061] 100 Methods of Making Headbands

[0062] 102 Provide bracket

[0063] 104 Arranging the bracket in the injection molding tool

[0064] 106 Forming Suspension

[0065] 200 Injection Molding Tools

[0066] 202 Lower forming part of injection molding tool

[0067] 204 Inserts for injection molding tools

[0068] 206 Upper forming part of injection molding tool

[0069] 300 headband

[0070] 302 bracket

[0071] 304 Suspension

[0072] 306 attachment points

[0073] 308 attachment points

[0074] 310 head gasket

[0075] 312 Cable

[0076] 314 bracket end

[0077] 316 bracket end

[0078] 318 telescopic extension

[0079] 320 telescopic extension

[0080] 322 ear cups

[0081] 324 ear cups

[0082] 326 Microphones

[0083] 400 headphones.

Claims

1. A method of manufacturing a headband for headphones, the headband comprising a bracket and a suspension, and the headband is configured to carry at least one ear cup of the headphones, the method comprising the following steps: - providing the support; - arranging the bracket in an injection molding tool, wherein the injection molding tool comprises a bracket cavity for placing the bracket and a suspension cavity for forming the suspension, the bracket cavity comprising at least two sub-cavities for forming a forming part of a connection between the suspension and the bracket; - forming the suspension from a rubber material by overmolding so that the suspension forms at least two attachment points to the bracket at a first suspension end and a second suspension end, wherein the first suspension end and the second suspension end are equidistant from the midpoint of the bracket; wherein the overmolding step comprises: the rubber material is in a liquid state and injected under high pressure into the injection molding tool and coats the base material on the two attachment points while forming a pad; after the hardening of the rubber material, the bracket and the suspension are permanently joined together as a single component, wherein the suspension forms a headrest extending between the first suspension end and the second suspension end; and Wherein the suspension is configured to cushion at the top of the user's head and abut the head when the headband is in use.

2. The method for manufacturing a headband for headphones according to claim 1, wherein: The rubber material is overmolded around the bracket in one processing step.

3. The method of manufacturing a headband for headphones according to claim 1, further comprising the step of molding at least one telescopic extension for the headband.

4. The method of manufacturing a headband for headphones according to claim 3, further comprising the step of assembling the at least one telescopic extension to the headband.

5. The method for manufacturing a headband for headphones according to claim 2, wherein: Overmolding the rubber material around the bracket includes: - overmolding said rubber material around said bracket to form two said attachment points; and - providing the head pad spaced apart from the support, the head pad being configured to cushion the head of the wearer; Thereby, a portion of the support located between two of the attachment points is configured to hover above the headrest and the wearer's head.

6. The method for manufacturing a headband for headphones according to claim 2, wherein: The suspension is overmolded around the bracket to completely encapsulate the bracket.

7. A headband for a headset manufactured by the method according to claim 1, the headband comprising a support and a suspension and configured to carry at least one ear cup of the headset.

8. A headband for a headset, the headband being configured to carry at least one ear cup of the headset, the headband comprising: - a bracket that bends to fit any wearer's head, - a suspension formed of a rubber material by overmolding and attached to the support at at least two attachment points, wherein the suspension forms a head cushion and is configured to rest at the top of and abut against the wearer's head when the headband is in use; - wherein the bracket provides a clamping force and the suspension can act by fine-tuning the clamping force; wherein the influence of the suspension on the clamping force is reduced by merely placing the rubber material on the outer surface of the bracket so that the rubber material deforms following the bracket; Wherein, the two attachment points are arranged at equal distances from the midpoint of the bracket.

9. The headband for headphones according to claim 8, wherein: The suspension includes a first rubber material portion and a second rubber material portion, the first rubber material portion forming the attachment point, the second rubber material portion being spaced apart from the first rubber material portion, the second rubber material portion being configured to cushion on the wearer's head such that the first rubber material portion is configured to hover above the second rubber material portion and the wearer's head.

10. A headband for headphones according to claim 9, wherein: The headband also includes at least one telescoping extension slidably disposed on an end of the headband.

11. The headband for headphones according to claim 10, wherein: The at least one telescopic extension is arranged on the headband by a hook.

12. The headband according to claim 9, wherein: The second rubber material portion has a concave shape when viewed in a cross section facing the first rubber material portion.

13. The headband for headphones according to claim 8, wherein: The bracket is a metal bracket formed into a curved shape.

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