DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0029] FIG. 1 illustrates a preferred embodiment of a monitor 10 disposed within a headrest 12 . The headrest 12 is mounted to a vehicle seatback 14 , and 12 is movable independently of the seatback 14 toward and away from the seatback 14 . The monitor 10 preferably faces a rear of the vehicle so that images displayed on the monitor 10 are visible to passengers seated behind the seatback 14 . Features of the monitor 10 , which are described in detail below, reduce the risk of injury to passengers presented by the monitor 10 , and enable the monitor 10 to be mounted in the very limited space available within a typical vehicle headrest 12 .

[0030] As shown in FIGS. 4, 5A and 5 B, the monitor 10 includes a screen structure 16 that is pivotably attached to a housing 18 . Both the housing 18 and an outer casing of the screen structure 16 are preferably constructed of a high-strength plastic, so that the monitor 10 is lightweight and durable. The housing 18 , which is embedded in the headrest 12 as shown in FIGS. 1, 7A and 7 B, includes a cavity 20 ( FIGS. 3, 4 and 5 B) defining a storage space for the screen structure 16 . The cavity 20 is substantially the same size and shape as the screen structure 16 , such that when the screen structure 16 is in the storage position of FIGS. 5A and 7A , a front face 22 of the screen structure 16 is substantially flush with an outer surface 24 of the housing 18 , which is in turn substantially flush with a surface 25 of the headrest 12 ( FIG. 7A ). The monitor 10 thus preferably protrudes only minimally or not at all from the headrest 12 .

[0031] In the illustrated embodiment, the screen structure 16 includes a front portion 26 ( FIGS. 2A and 2B ) that is a substantially rectangular parallelepiped, and a rear portion 28 that tapers inward from the front portion 26 toward a rear face 30 . Each of the left and right faces 32 , 34 of the screen structure 16 includes a first hinge portion 36 adjacent a top face 38 of the screen structure 16 . Each hinge portion 36 comprises a substantially flat bar 40 defining a plane that is parallel to a side face 32 , 34 of the screen structure 16 . The bar 40 is pivotably secured at a first end 42 to the side face 32 , 34 of the screen structure 16 , such that the bar 40 is pivotable in the plane defined by the bar 40 . The first hinge portions 36 cooperate with second hinge portions 44 (FIGS. 3 A- 3 C) on the housing 18 to pivotably secure the screen structure 16 to the housing 18 , as described in detail below. The illustrated first hinge portions 36 are preferred, because they simplify the assembly of the monitor 10 , as explained below. However, those of skill in the art will appreciate that a variety of alternate hinge constructions could be used and still achieve a number of advantages of the present monitor 10 .

[0032] The front surface 22 of the screen structure 16 ( FIG. 1A ) includes a viewing screen 46 that displays images to passengers. As shown in FIGS. 2A and 2B , the screen structure 16 includes an input cable 48 for receiving an input signal to control the images displayed on the viewing screen 46 . A first end 50 of the cable preferably includes a multi-pin connector 52 that enables a variety of input devices to selectively communicate with the monitor 10 .

[0033] The monitor 10 further includes a plurality of controls for determining characteristics of the displayed images. For example, one control preferably enables power to be selectively applied to the monitor 10 . Other controls preferably enable a viewer to select between various input sources for the monitor 10 , such as a television tuner, a DVD player, a video game system, etc. Other controls preferably enable adjustment of qualities of the screen images, such as brightness, sharpness, contrast, etc.

[0034] In the illustrated embodiment, a first cluster of manual controls 54 is located on the front face 22 of the screen structure 16 , and a second cluster of manual controls 56 is located on the outer surface 24 of the housing 18 adjacent the screen structure 16 . The front face 22 of the screen structure 16 further includes an infrared sensor 58 for receiving signals from a handheld wireless remote control unit (not shown). Those of skill in the art will appreciate that all controls may be located on the screen structure 16 , or all controls may be located on the housing 18 . Alternatively, the monitor 10 may include no integrated manual controls, such that the monitor 10 is controllable using only a handheld wired or wireless remote control unit.

[0035] An interior of the screen structure 16 preferably includes at least one speaker 59 that produces audible sounds that accompany the images displayed on the screen 46 . At least one of the controls 54 , 56 on the monitor 10 or on an optional remote control unit preferably enables adjustment of a volume level produced by the at least one speaker 59 . The rear face 30 of the screen structure 16 , shown in FIG. 2 B, includes apertures 60 that enable sounds produced by the speaker 59 to be heard clearly by passengers. Those of skill in the art will appreciate that the apertures 60 are not necessary to achieve many advantages of the present monitor 10 .

[0036] Those of skill in the art will also appreciate that the monitor 10 need not include a speaker 59 . The monitor 10 could, for example, be connected to the vehicle's sound system such that sounds from the monitor 10 are produced by speakers mounted in the vehicle's interior. However, front seat passengers, who are not in a position to view the images on the monitor 10 , may wish to listen to, for example, a radio broadcast through the vehicle's sound system. Therefore, providing at least one speaker 59 in the monitor 10 enables rear seat passengers to listen to sounds produced by the monitor 10 , and front seat passengers to listen to sounds produced by the vehicle's sound system. To eliminate any dissonance created by two sources of different sounds, the monitor 10 could also include a headphone jack so that only backseat passengers wearing headphones can hear sounds produced by the monitor 10 .

[0037] As shown in FIGS. 3 A- 3 C, 5 A and 5 B, front edges of the housing 18 extend outward and backward, thus creating a rim 62 around the cavity 20 having a front face 64 and side faces 66 , 68 , 70 , 72 that are substantially parallel to side faces of the cavity 20 . The rim 62 increases the rigidity of the housing 18 without substantially increasing its weight or volume. In the illustrated embodiment, a portion of the front face 64 of the rim 62 adjacent a lower right edge 68 of the housing 18 includes a plurality of apertures 74 . The apertures 74 are adapted to house controls, such as buttons or knobs, for adjusting various aspects of the monitor 10 , as described above. Those of skill in the art will appreciate that the apertures 74 are not necessary to achieve all the advantages of the monitor 10 , since controls may be mounted on the screen structure 16 or on a remote control unit.

[0038] A floor 76 of the cavity 20 preferably includes a plurality of apertures 78 ( FIG. 3A ) that cooperate with mounting hardware, such as screws, to secure the housing 18 to the headrest 12 . The floor 76 preferably also includes an aperture 80 of sufficient size to allow the input cable 48 to pass through the floor 76 without interference. A top surface 82 , bottom surface 84 and opposing side surfaces 86 extend upward from the floor 76 . The floor 76 protects the monitor 10 and the headrest 12 during use.

[0039] Adjacent the top surface 82 , each side surface 86 of the cavity 20 includes a second hinge portion 44 (FIGS. 3 A- 3 C) that cooperates with one of the first hinge portions 36 on the screen structure 16 to pivotably secure the screen structure 16 to the housing 18 . Each second hinge portion 44 comprises a slot having a width substantially equal to a thickness of the bar 40 of the first hinge portion 36 . The bar 40 is thus slidable within the slot. With the bar 40 disposed within the slot, a position and orientation of the bar 40 is fixed relative to the housing 18 . However, because the bar 40 is rotatable with respect to the screen structure 16 , the screen structure 16 is pivotable with respect to the housing 18 .

[0040] A tab 88 within the slot cooperates with an aperture 90 ( FIG. 2A ) on the bar 40 to lock the bar 40 within the slot. The tab 88 is cantilevered and attached to a side edge 92 of the floor 76 of the cavity 20 . The tab 88 includes a forward facing tapered portion 94 ( FIG. 3C ) that terminates in a ledge 96 that is perpendicular to a longitudinal axis of the tab 88 and faces away from the rim 62 . As the bar 40 is inserted within the slot, the bar 40 slides along the outside of the tab 88 , and the bar 40 urges the tab 88 inward due to interengagement of the bar 40 with the tapered surface 94 . As a leading edge 98 ( FIG. 2A ) of the bar 40 reaches a rear end of the slot, the tab 88 snaps into position within the aperture 90 of the bar 40 . The ledge 96 abuts an edge of the aperture 90 , thus locking the bar 40 within the slot and securing the screen structure 16 to the housing 18 . The present monitor 10 is thus easy to assemble. The bars 40 are simply inserted into the slots until the tabs 88 lock into place within the apertures 90 .

[0041] While the illustrated second hinge portions 44 are preferred for their ease of assembly together with the illustrated first hinge portions 36 , those of skill in the art will appreciate that the illustrated second hinge portions 44 are merely exemplary. A variety of alternate hinge constructions could be used to achieve many advantages of the present monitor 10 .

[0042] Preferably, the first and second hinge portions 36 , 44 are located near an upper edge 38 , 82 of the screen structure 16 and housing 18 , respectively. The upper edge 38 of the screen structure 16 thus remains substantially fixed with respect to the housing 18 , while a lower edge 100 of the screen structure 16 is capable of protruding substantially from the front face 24 of the housing 18 , as shown in FIG. 5B . Preferably, a finger catch 102 ( FIGS. 2A, 2B , 5 A and 5 B) extends downward from the lower edge 100 of the screen structure 16 . The finger catch 102 provides a convenient surface against which a viewer may place his or her fingers to rotate the screen structure 16 with respect to the housing 18 . Preferably, the lower edge 70 of the housing includes a cut out portion 104 ( FIGS. 3A and 4 ) so that a viewer can reach behind the finger catch 102 to pull the screen structure 16 outward from the stowed position of FIG. 5A .

[0043] Advantageously, as the screen structure 16 pivots from the stowed position of FIG. 5A to the position of FIG. 5 B, no portion of the rear face 30 of the screen structure 16 moves toward the floor 76 of the cavity 20 . The floor 76 thus defines a limit for the monitor 10 . No portion of the monitor 10 , including the screen structure 16 , extends beyond the floor 76 into the headrest 12 . Thus, the overall monitor 10 occupies relatively little depth of the headrest 12 , because the depth occupied by the monitor 10 corresponds roughly to the thickness of the screen structure 16 .

[0044] With prior art monitors, such as the monitors disclosed in U.S. Pat. Nos. 5,267,775 to Nguyen, 5,507,556 to Dixon, and 5,842,715 to Jones, additional depth beyond the thickness of the screen structure would be required within a headrest to accommodate these monitors. As the screen structures of these monitors pivot from the stowed position to a viewing position, an upper edge of the screen structure would move backward into the headrest. This configuration is disadvantageous because limited space is available within a headrest.

[0045] The function of a headrest is to provide padding for comfort and safety. Thus, a headrest must comprise at least a minimum amount of padding. When a monitor is added to a headrest, padding is displaced. The padding may be eliminated entirely, but such elimination makes the headrest less comfortable and less safe. Alternatively, the padding may be retained but moved elsewhere within the headrest. Disadvantageously, this option makes the headrest larger. If the headrest is made wider, the extra width obstructs a larger portion of the driver's view. If instead the headrest is made deeper, (extends farther into rear passenger area) the portion of the headrest that protrudes into the rear passenger area presents an obstacle to rear seat passengers. Therefore, a headrest-mounted monitor desirably occupies minimal space.

[0046] Besides defining a thickness of the present monitor 10 , the housing 18 also provides a self-contained casing for the monitor 10 . The housing 18 thus protects the monitor 10 from impacts, for example. The housing 18 also facilitates installation and removal of the monitor 10 . To exchange one monitor 10 for another, for example if the first monitor 10 is defective, the housing 18 and all of the components within the housing are easily removed from the headrest 12 . A new monitor 10 is then easily installed by inserting the housing 18 of the new monitor 10 into the headrest 12 .

[0047] As shown in FIGS. 4, 5A and 5 B, the monitor 10 includes a bracket 106 that limits a range of pivot of the screen structure 16 relative to the housing 18 . The shape of the bracket 106 , illustrated in FIG. 6 , preferably resembles a straight wire 108 with an attached pair of L-shaped wires 110 . Of course, the bracket 106 may be produced by many different processes such that the straight wire 108 and L-shaped wires 110 comprise one piece, or separate pieces attached to one another.

[0048] All three wires 108 , 110 , 110 are coplanar, and both L-shaped wires 110 extend from the straight wire 108 in the same direction. The upright portion 112 of each L-shaped wire 110 is substantially perpendicular to the straight wire 108 , and the base portion 114 of each L-shaped wire 110 is substantially parallel to the straight wire 108 . Further, the base portions 114 of each L-shaped wire 110 extend toward each other, and include a small gap 116 between their ends. The upright portions 112 of the L-shaped wires 110 are attached to the straight wire 108 such that opposite end portions of the straight wire 108 , comprising posts 118 , extend beyond the attachment points of the L-shaped wires 110 .

[0049] The base portions 114 of the L-shaped wires 110 , which define a first end 124 of the bracket 106 , are pivotably retained within a tube 120 ( FIGS. 3A, 4 and 5 A- 5 B) on the floor 76 of the cavity 20 . The tube 120 defines a first pivot opening and a second pivot opening. The posts 118 of the straight wire 108 , which define a second end 126 of the bracket 106 , are slidably retained within a channel 122 on the rear face 30 of the screen structure 16 , as shown in FIGS. 2B, 5A and 5 B. In the stowed position shown in FIG. 5 A, the bracket 106 is substantially parallel to the rear face 30 of the screen structure 16 . As the screen structure 16 pivots outward from the cavity 20 , the base portions 114 of the L-shaped wires 110 pivot within the tube 120 and the posts 118 slide downward within the channel 122 . As FIG. 5B illustrates, the posts 118 eventually reach a lower end of the channel 122 , defining a maximum angle of the screen structure 16 relative to the housing 18 .

[0050] Preferably, the hinges 36 , 44 that pivotably connect the screen structure 16 to the housing 18 are self tensioning. Thus, the hinges 36 , 44 retain the screen structure 16 in the position of FIG. 5 B, and in any position in between the positions of FIG. 5 A and FIG. 5B . A viewer can thus position the screen structure 16 anywhere between the limits of rotation to enjoy the optimum viewing angle. For example, the optimum viewing angle often depends upon the position of the sun. Glare from sunlight interferes with the viewer's ability to see images on the screen. Thus, the viewer can orient the screen structure 16 such that glare from sunlight is minimized. Furthermore, as the vehicle travels, its position and orientation with respect to the sun are continuously changing. At one moment, there may be little or no glare on the screen 46 , and the next moment the vehicle may round a comer and suddenly there is a substantial glare on the screen 46 . Because the present monitor 10 is positionable in a wide range of viewing angles, the monitor 10 enables the viewer to continuously adjust the angle of the screen structure 16 to avoid sun glare occasioned by variations in the vehicle's position and/or orientation with respect to the sun.

[0051] The present monitor 10 advantageously collapses toward the storage position ( FIGS. 5A and 7A ) when a force F is applied to the front surface 22 of the screen structure 16 as shown in FIGS. 5B and 7B . This feature is especially advantageous when a vehicle in which the monitor 10 is installed collides with another vehicle or brakes suddenly, for example. In these situations, a passenger seated behind the monitor 10 is often thrown forward, and may collide with the monitor 10 . If the monitor 10 does not quickly collapse upon contact, the monitor 10 could injure the passenger.

[0052] As shown in FIG. 5 B, the bracket 106 limits the rotation of the screen structure 16 relative to the housing 18 . The length of the bracket 106 is fixed, and the first end 124 of the bracket 106 is constrained against translation. Therefore, a maximum angle that the screen structure 16 can be rotated from the stowed position of FIG. 5A coincides with a configuration wherein a longitudinal axis of the bracket 106 is perpendicular to the rear face 30 of the screen structure 16 . In such a configuration, a force applied perpendicularly to the front face of the screen structure 16 , such as the force F in FIG. 5 B, would not have a component that acts on the bracket second end 126 in a direction parallel to the channel 122 and perpendicular to the bracket 106 . Instead, the entire magnitude of the force would act in a direction parallel to the bracket 106 , and would not cause the bracket second end 126 to slide upward within the channel 122 , thus rotating the bracket 106 about its first end. In such a configuration, the bracket 106 would prevent the screen structure 16 from rotating back toward the storage configuration of FIG. 5A . The screen structure 16 would thus pose a danger to a passenger colliding with it, as in a crash or a sudden stop.

[0053] However, as explained above and illustrated in FIG. 5B, a lower end of the channel 122 in the rear face 30 of the screen structure 16 limits the travel of the bracket 106 within the channel 122 and prevents the bracket 106 from reaching the configuration wherein the bracket 106 is perpendicular to the rear face 30 of the screen structure 16 . As shown in FIG. 5 B, the maximum angle a between the bracket 106 and the rear face 30 of the screen structure 16 is preferably about 80°, and more preferably about 75°. In this configuration, the force F applied perpendicularly to the front face 22 of the screen structure 16 has a component that acts parallel to the channel 122 , and a component that acts perpendicularly to the bracket 106 . These force components cause the bracket second end 126 to translate upward within the channel 122 , causing the bracket 106 to rotate about its first end 124 as the screen structure 16 collapses toward the storage configuration of FIG. 5A . The bracket 106 thus diminishes the injury-causing potential of the monitor 10 by enabling the screen structure 16 to pivot safely out of the way when a passenger collides with it.

[0054] Scope of the Invention

[0055] The above presents a description of the best mode contemplated for the present headrest-mounted monitor, and of the manner and process of making and using it, in such full, clear, concise, and exact terms as to enable any person skilled in the art to which it pertains to make and use this headrest-mounted monitor. This headrest-mounted monitor is, however, susceptible to modifications and alternate constructions from that discussed above which are fully equivalent. Consequently, it is not the intention to limit this headrest-mounted monitor to the particular embodiments disclosed. On the contrary, the intention is to cover all modifications and alternate constructions coming within the spirit and scope of the headrest-mounted monitor as generally expressed by the following claims, which particularly point out and distinctly claim the subject matter of the headrest-mounted monitor.