(12) Ulllted States Patent
`(10) Patent N0.:
`US 6,295,366 B1
`
`Haller et al.
`(45) Date of Patent:
`Sep. 25, 2001
`
`US006295366B1
`
`(54) AIRCRAFT HEADSET
`
`1/1999 Nelson ................................. 381/371
`5,862,241 *
`5,970,160 * 10/1999 Nilsson et al.
`....................... 381/370
`
`(75)
`
`Inventors: Larry D. Haller, Hillsboro; Charles E.
`Inmon, Lake Oswego; Christopher J.
`Jensen, Hillsboro; James D. Pileggi,
`Beaverton; Brian VanderPloeg, Lake
`Oswego; Stevan L. VVittenbrock,
`Portland, all of OR (US)
`
`,
`( * ) Notice:
`
`(73) Assignee: Flightcom Corporation, Portland, OR
`(US)
`,
`,
`,
`,
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U'S'C' 1540)) by 0 days.
`
`(21) Appl. NO‘: 09/275,513
`(22)
`Filed:
`Mar. 24, 1999
`
`Int. Cl.7 ..................................................... H04R 25/00
`(51)
`........... 381/374; 381/370; 381/371;
`(52) US. Cl.
`
`381/375; 381/376; 381/378; 381/379; 379/430
`('58) Field of Search ..................................... 381/370, 371,
`381/372, 375, 376, 377, 378, 379, FOR 149,
`FOR 150; 181/128, 129, 137; 379/430;
`455/90
`
`(56)
`
`References Cited
`U.S. PATENT DOCUMENTS
`12/1991 Urella .
`1/1997 Runquist .
`381/372
`7/1952 Kettler
`
`2/1986 Gorike ............................... 381/370
`5/1990 saplelewsh ‘
`12/1990 Sapiejewski.
`
`D. 322,440
`D. 377,174
`2,603,724 *
`4,571,746 *
`499227542
`4,975,966
`
`4,987,592 *
`4,989,271
`5,095,382 *
`5,185,807 *
`5,708,725 *
`5,793,878 *
`
`.................................... 381/375
`1/1991 Flagg.
`2/1991 Saplejewskl et al.
`.
`3/1992 Abe ...................................... 381/378
`2/1993 Bergin et al.
`381/374
`
`1/1998 Ito ..........
`381/370
`8/1998 Chang .................................. 381/370
`
`OTHER PUBLICATIONS
`New Headphone For Every Head, Nov. 1980*
`Only Sony Offers the Most Advanced Headsets for Every
`Mindset, Nov. 1980*
`*
`.
`.
`Cited by examiner
`
`Primary Examiner—Curtis Kuntz
`Assistant Examiner—Suliari Ni
`(74) Attorney, Agent, or Firm—Robert D. Varitz, PC
`
`ABSTRACT
`(57)
`An aircraft headset includes a headset band, including a head
`element and a pair of ear cup supports slidably received in
`the head element, ear cups pivotally attached at one end of
`each ear cup support; and a microphone boom pivotally
`attached to one of the ear cups; an improved ear cup
`tensioning mechanism including a tongue extending later-
`ally from each end of the headset band and a conformal
`tonguc rcccivcr locatcd adjaccnt thc other cnd of each car
`cup support; wherein the tongue receiver is conformal with
`the tongue, and wherein the tongue and the tongue receiver
`are constructed and arranged to provide near-constant lateral
`pressure between the ear cups and a wearer’s head. An
`improved ear cup seal
`includes an outer seal covering
`formed of urethane—coated expanded vinyl; an inner flexible
`hayer formed of scythed urethane foam; wherein the inner
`ex1b1e layer has a memory which returns the ear seal to its
`original configuration when pressure is released therefrom,
`and wherein the ear cup seal has a variable configuration
`having its thickest region behind and below a wearer‘s ear,
`along the wearer’s neck, and having its thinnest region
`adjacent the front of the wearer’s car along the jaw line. An
`~
`~
`~
`~
`improved microphone housmg includes a hard outer shell
`havin
`a cavit
`th
`.
`.
`d
`d- b
`b.
`t
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`1
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`“cm an
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`10“th “151010910 01”“ Shell Wthh “101050 the “(3011110no
`element
`
`8 Claims, 5 Drawing Sheets
`
`
`
`Bose Exhibit 1035
`
`Bose v. Koss
`
`

`

`US. Patent
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`Sep. 25, 2001
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`Sheet 1 0f 5
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`US 6,295,366 B1
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`Sep. 25, 2001
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`Sheet 2 0f 5
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`US 6,295,366 B1
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`Fig. 2
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`Sep. 25, 2001
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`Sheet 3 0f 5
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`US. Patent
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`US. Patent
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`Sep. 25, 2001
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`Sheet 5 0f 5
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`

`US 6,295,366 B1
`
`1
`AIRCRAFT HEADSET
`
`FIELD OF THE INVENTION
`
`This invention relates to headsets intended primarily for
`use in aircraft, and specifically to a headset that provides
`extended wear comfort and provides enhanced background
`noise reduction.
`
`BACKGROUND OF THE INVENTION
`
`Headsets generally include a headband that incorporates,
`or is made from, a spring, which passes over the head of the
`user and presses the ear cups to the wearer’s head with some
`predetermined force. Some mechanism is provided to allow
`the length of the headband to change, such as providing a
`headband element having a hollow cavity therein, which
`cavity receives sliding elements, which are attached to the
`ear cups. The headband also provides vertical support to
`keep the ear cups from slipping off the wearer’s ears under
`the influence of gravity or other G forces.
`The tension supplied by the headband is in the form of a
`bending moment transmitted along the components of the
`headband. If the material of the headband, the stress, and
`bending moment are nearly constant,
`the only variables
`which remain are the width and thickness of the band.
`However, as the headset is adjusted for different wearers, or
`as a single wearer changes the location of the headset on the
`wearer’s head, the moment changes, as the distance between
`the headband element and the ear cup changes. While it is
`desirable to provide a constant, evenly disbursed headband-
`gcncrated force on the ear cups, changing the bending
`moment of the headband changes the lateral force applied by
`the headband in prior art systems.
`Another feature of aircraft headsets is noise reduction so
`
`that a headset wearer (1) can hear sound generated by
`transducers in the ear cups over the aircraft background
`noise, which is accomplished by providing an acoustic seal
`between the wearer’s head and the ear cup; and (2) generate
`a signal from a microphone, usually attached to one of the
`ear cups, wherein the background noise from the aircraft is
`minimized by the microphone pickup. The present invention
`embodies an improved headphone ear seal
`that further
`improves comfort while providing a good
`Prior art cushions have incorporated a variety of non-
`liquid gelatin-like material on a ring of soft, slow recovery
`foam enclosed within a thin stretchable layer of polyure-
`thane skin. A variety of configurations have been used,
`including multiple rings of cushioning, various thicknesses
`and duromctcr ratings of material, etc. The known prior art
`has presented cushions of uniform cross-section, while fail-
`ing to consider the shape of the human head.
`Likewise, microphone pickups have used a variety of
`dampening materials to eliminate pickup of vibrations from
`the headset and to reduce wind and pop noises. These
`systems have generally placed sound-dampening materials
`outside the microphone housing, and have proven less than
`adequate.
`
`SUMMARY OF TIIE INVENTION
`
`An aircraft headset includes a headset band, including a
`head element and a pair of ear cup supports slidably received
`in the head element, ear cups pivotally attached at one end
`of each car cup support; and a microphone boom pivotally
`attached to one of the ear cups; an improved ear cup
`tensioning mechanism including a tongue extending later-
`ally from each end of the headset band and a conformal
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`2
`tongue receiver located adjacent the other end of each ear
`cup support; wherein the tongue receiver is conformal with
`the tongue, and wherein the tongue and the tongue receiver
`are constructed and arranged to provide near-constant lateral
`pressure between the ear cups and a wearer’s head. An
`improved ear cup seal
`includes an outer seal covering
`formed of urethane-coated expanded vinyl; an inner flexible
`layer formed of scythed urethane foam; wherein the inner
`flexible layer has a memory which returns the ear seal to its
`original configuration when pressure is released therefrom,
`and wherein the ear cup seal has a variable configuration
`having its thickest region behind and below a wearer’s ear,
`along the wearer’s neck, and having its thinnest region
`adjacent the front of the wearer’s ear along the jaw line. An
`improved microphone housing includes a hard outer shell
`having a cavity therein; and sound-absorbing material
`located inside the outer shell which enclose the microphone
`element.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`FIG. 1 is front elevation of a headset constructed accord-
`
`ing to the invention.
`FIG. 2 is a top plan view of a near-constant pressure
`mechanism of the invention.
`
`FIG. 3 is a bottom plan view of the near-constant pressure
`mechanism of FIG. 2.
`
`FIG. 4 is an interior view of an ear cup and ear seal of the
`invention.
`
`FIG. 5 is a front elevation of the ear cup and ear seal of
`FIG. 4, with portions broken away to show interior detail of
`an ear cup seal of the invention.
`FIG. 6 is a top plan view of the ear cup and ear seal of
`FIG. 4.
`
`FIG. 7 is a rear elevation of the ear cup and ear seal of
`FIG. 4.
`
`FIG. 8 is a perspective view of an ear cup seal of the
`invention.
`
`FIG. 9 is a front elevation of the ear cup seal of FIG. 8.
`FIG. 10 is a left side elevation of the ear cup seal of FIG.
`8, with portions broken away to show detail.
`FIG. 11 is a right side elevation of the ear cup seal of FIG.
`
`8.
`
`FIG. 12 is a bottom plan view of the car cup seal of FIG.
`
`8.
`
`FIG. 13 is a top plan view of a microphone holder of the
`invention, with portions broken away to show detail.
`FIG. 14 is a rear elevation of the microphone holder of
`FIG. 13.
`
`FIG. 15 is a front elevation of the microphone holder of
`FIG. 13.
`
`DETAILED DESCRIPTION OF THE
`PREFERRED EMBODIMENT
`
`Referring now to FIG. 1, a headset is shown generally at
`20. Headset 20 includes a headband 22, spaced apart ear
`cups 24, 26, and a microphone boom 28.
`Headband 22 includes a head element 30, having a head
`cushion 32 carried on the bottom side thereof. A pair of ear
`cup supports 34, 36 is moveable on head element 30,
`to
`provide adjustment for ear cups 24, 26, respectively. Each
`ear cup 24, 26, is pivotally mounted on its respective ear cup
`support 34, 36, and includes a ear cup, or acoustic, seal 38,
`40. A cord 42 extends from ear cup 26 and provides an
`
`

`

`US 6,295,366 B]
`
`3
`electrical connection to acoustic transducers (not shown)
`mounted in ear cups 24, 26, and to a microphone pickup
`element carried in a microphone housing 44, located at one
`end of microphone boom 28. Volume control knobs 46 are
`located on each ear cup to control the volume of the acoustic
`transducers located in each ear cup.
`Turning now to FIGS. 2 and 3, an object of headset 20 is
`to provide a near-constant lateral pressure between ear cup
`seals 38, 40, and a wearer’s head. To this end, the structure
`surrounding a sliding joint 50, located between head element
`30 and the ear cup supports, such as ear cup support 34,
`which allows an ear cup support to move into and out of a
`cavity (not shown)
`in head element 30. A tongue-like
`structure, shown generally at 52,
`includes a tongue 54,
`which extends outward and downward from either end of
`
`head element 30, over ear cup support 34, as shown in FIG.
`2. Ear cup support 34 has a tongue receiver 56 that is
`conformal with tongue 54, and fully contacts tongue 54
`when ear cup support 34 is fully inserted into head element
`30. Tongue 54 contacts tongue receiver 56 only at tongue tip
`54a as ear cup support 34 is withdrawn from head element
`30. Referring to FIG. 3,
`the structure is shown on the
`underside of headband 22, and depicts the underside of the
`tongue receiver 56 of ear cup support 34. Also depicted is a
`stilfening structure 58, which is located on the underside of
`ear cup support 34. Acable channel runs along the underside
`of the ear cup supports, which have a generally inverted
`T—shaped configuration (not shown), wherein a cable extend-
`ing between earcups 24, 26 is carried in the stem of the “T”.
`When an ear cup support is extended from head element
`30, tongue 54 and tongue receiver 56 cooperate with the ear
`cup support to provide a near-constant bending moment on
`the ear cup support, which, in turn, provides the lateral force
`on the ear cup and the ear cup seal, as tongue 54 controls and
`limits relative upward and outward bending of ear cup
`support 34.
`Turning now to FIGS. 4—12, the acoustic seal will be
`described in greater detail. The acoustic seal, and using ear
`cup seal 38 as an example, includes an inner cushion 62 of
`a dense, resilient foam, best seen in the cut-away portions of
`FIGS. 5 and 10. This structure allows the seal to conform to
`
`the wearer’s head when in place, and to resume its original
`configuration after it is removed from the wearer’s head. An
`outer covering 60 of the seal is formed,
`in the preferred
`embodiment, of 30 mil expanded Vinyl, and is both vacuum
`formed and precut to the desired configuration, which will
`be described in more detail later herein. Covering 60 is
`coated, in the preferred embodiment, with a one mil thick
`layer of urethane ink, to provide additional environmental
`durability, i.e., to protect covering 60 from the effects of
`atmospheric and skin-carried contaminants. Interior filling
`62 is formed of four-pound per cubic foot scythed urethane
`foam, formed in the desired shape and enclosed within
`covering 60, without over stuffing.
`Ear cup seal 38 has an irregular shape in order to easily
`conform to a wearer’s head. The seal has a thickness of
`
`between 0.85" and 0.65", and is thickest in the region in
`contact with the wearer’s head about the lower margins of
`the wearer’s ears and to the rear thereof. The thinnest portion
`of the ear cup seal is located in front of the wearer’s ear, and
`adjacent to lower margin thereof, extending along the jaw
`line. This configuration provides the improved acoustic seal
`of the invention, which is in full contact with the wearer’s
`head along the contours thereof, particularly along the jaw
`line and neck, which are areas subject to gaps with conven-
`tional ear seals. The configuration also provided an ear seal
`of minimal thickness.
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`4
`Referring now specifically to FIGS. 5 and 10, a backing
`plate 66 is located within ear cup seal 38 to attach the seal
`to the ear cup. Backing plate 66 includes a flat annular ring
`68 having a central orifice 70 therein. Ring 68 has a series
`of snap hook structures 72 protruding from the rear surface
`thereof, which cooperate with a groove 76 extending about
`the inner periphery of each ear cup, also referred to herein
`as an ear cup seal receiver, to hold the ear cup seal on the ear
`cup. As best shown in FIG. 10, covering 60 includes a
`formed portion 60a and a backing portion 60b. Backing
`portion 60b is precut from the Vinyl material and has holes
`formed therein to allow passage of snap hook structures 72.
`Formed portion 60a is attached to backing portion 60b, in
`the preferred embodiment by RF welding, with backing
`plate 66 and inner cushion 62 sealed therein, and with snap
`hook structures 72 extending through holes formed in back-
`ing portion 60b.
`Turning now to FIGS. 1 and 13715, the microphone of the
`invention will be further described. Microphone boom 28
`extends from left ear cup 26. The boom is a flexible material
`and is rotatable on a pivot on ear cup 26, so that it may be
`moved upward to a position over the wearer’s head, or
`downward to an operable position in front of the wearer’s
`mouth. Microphone housing 44 is attached to one end of
`boom 28. Housing 44 includes an endcap 80, which is
`received on the end of boom 28, and which has a cylindrical
`opening therein, forming an open cavity 82 therein. Cavity
`82 encloses a microphone pickup element 84, of the bidi-
`rectional type. Felt discs 86, 87 are placed on the front and
`rear, respectively of pickup element 84. Discs 86, 87 protect
`element 84 from dust and any spray which may invade the
`interior of housing 44.
`A foam buffer 88 is placed in cavity 82 on the side of
`microphone pickup element 84 facing the user. Buffer 88 is
`formed of urethane foam, and is approximately one-eight on
`an inch thick. Buffer 88 functions as a plosive sound
`absorbing mechanism,
`to absorb “puff” sounds associated
`with the plosive consonants, i.e., b, p, t, and numbers 2, 4
`and 5.
`
`Afront housing element 92 and a re ad housing element 94
`are secured to endcap 80. This arrangement provides a hard
`exterior for the microphone, in the form of housing 44, while
`the felt and foam layers provide a soft cushion for micro-
`phone pickup element 84 which reduces the amount of
`background noise that is picked up and transmitted through
`microphone element 84.
`Although a preferred embodiment of the invention has
`been disclosed herein,
`it will be appreciated that futher
`variations and modification may be made thereto without
`departing from the scope thereof as defined in the appended
`claims.
`We claim:
`
`1. In an aircraft headset having a headset band, including
`a head element and a pair of ear cup supports slidably
`received in the head element, ear cups pivotally attached at
`one end of each ear cup support; and a microphone boom
`pivotally attached to one of the ear cups; an improved ear
`cup tensioning mechanism] comprising:
`a generally flat, parabolic-like shaped tongue extending
`laterally from each end of the headset band and a
`conformal tongue receiver located adjacent the other
`end of each ear cup support; wherein said tongue
`receiver is conformal with said tongue, and wherein
`said tongue and said tongue receiver are constructed
`and arranged to provide near-constant lateral pressure
`between the ear cups and a wearer’s bead.
`
`

`

`US 6,295,366 B]
`
`5
`2. The improved ear cup tensioning mechanism of claim
`1 wherein said tongue includes a narrowed tongue tip
`portion thereto, and wherein said tongue tip portion is in
`substantial point contact with said tongue receiver when an
`ear cup support withdrawn from the head element.
`3. An aircraft headset having a headset band, including a
`bead element and a pair of ear cup supports slidably received
`in the head element, ear cups pivotally attached at one end
`of each ear cup support; and a microphone boom pivotally
`attached to one of the ear cups; comprising:
`an ear cup tensioning mechanism including a generally
`flat, parabolic—like shaped tongue extending laterally
`from each end of the headset band and a conformal
`
`tongue receiver located adjacent the other end of each
`ear cup support; wherein said tongue receiver is con—
`formal with said tongue, and wherein said tongue and
`said tongue receiver are constructed and arranged to
`provide near—constant lateral pressure between the ear
`cups and a wearer’s head; and
`an ear cup seal having an outer seal covering formed of
`expanded vinyl;
`an inner flexible layer formed of scythed urethane foam;
`wherein said inner flexible layer has a memory which
`returns said inner flexible layer to its original configu-
`ration when pressure is released therefrom, and
`wherein said ear cup seal has a variable configuration
`having its thickest region adjacent
`the bottom of a
`wearer’s ear and behind thereof, and having its thinnest
`region in front of a wearer’s ear and ahead thereof.
`4. The aircraft headset of claim 3 wherein said outer seal
`covering includes a formed portion and a backing portion,
`and wherein said inner flexible layer is sealed within the
`portions of said outer seal covering; and which further
`includes a backing plate sealed between said backing portion
`and said inner flexible layer.
`
`10
`
`20
`
`25
`
`30
`
`6
`5. The aircraft headset of claim 4 wherein said backing
`plate includes snap hook structures for securing said ear cup
`seal to the ear cup seal receiver.
`6. The aircraft headset of claim 3 wherein said seal
`covering has a layer of urethane ink applied there over.
`7. An aircraft headset having a headset band, including a
`head element and a pair of ear cup supports slidably received
`in the head element, ear cups pivotally attached at one end
`of each ear cup support; and a microphone boom pivotally
`attached to one of the ear cups; comprising:
`an ear cup tensioning mechanism including a generally
`flat, parabolic-like shaped tongue extending laterally
`from each end of the headset band and a conformal
`tongue receiver located adjacent the other end of each
`ear cup support; wherein said tongue receiver is con—
`formal with said tongue, and wherein said tongue and
`said tongue receiver are constructed and arranged to
`provide near-constant lateral pressure between the ear
`cups and a wearer’s head; and
`a microphone housing including an endcap which is
`received on the end of the microphone boom, and
`which has a cylindrical opening therein, forming an
`open cavity;
`a bi-directional microphone pickup element received in
`said cavity, wherein said pickup element includes a felt
`disc fixed on the front and rear sides thereof, and
`wherein a foam sound absorbing mechanism is located
`said cavity on the front side of said microphone pickup
`element; and
`a front housing element and a rear housing element
`secured to said endcap to form, with said endcap, a hard
`exterior for the microphone.
`8. The aircraft headset of claim 7 wherein said foam buffer
`
`is formed of urethane foam, having a thickness of about
`one-eight on an inch thick.
`
`46
`
`X
`
`