Earphone sleeve assembly having integral barrier

An apparatus for blocking materials from entering the sound port of an earphone, while simultaneously allowing sound to pass through unaffected is disclosed. In an earphone having an elongated nozzle with a central opening adapted to transmit sound, a removable or replaceable a sleeve assembly having a wax guard or barrier is formed integral with the ear sleeve assembly. The barrier is mounted in a stem and is adapted to prevent materials from entering the central opening of the earphone nozzle. The stem is also adapted to receive the sleeve over its body. The sleeve can be cylindrical or tapered in shape, and the sleeve can be adapted to aid in blocking ambient noise. The barrier, the stem, and the sleeve can all be formed as an integral one-piece assembly, and the entire one-piece assembly can be adapted to be changed by the user.

TECHNICAL FIELD

Aspects of the disclosure relate to earphones for in-ear listening devices ranging from hearing aids to high quality audio listening devices to consumer listening devices, and more particularly, to a device and method for preventing cerumen (earwax) and debris from entering the nozzle or sound port of an in-ear listening device.

BACKGROUND

Personal “in-ear” monitoring systems are utilized by musicians, recording studio engineers, and live sound engineers to monitor performances on stage and in the recording studio. In-ear systems deliver a music mix directly to the musician's or engineer's ears without competing with other stage or studio sounds. These systems provide the musician or engineer with increased control over the balance and volume of instruments and tracks, and serve to protect the musician's or engineer's hearing through better sound quality at a lower volume setting. In-ear monitoring systems offer an improved alternative to conventional floor wedges or speakers, and in turn, have significantly changed the way musicians and sound engineers work on stage and in the studio.

Moreover, many consumers desire high quality audio sound, whether they are listening to music, DVD soundtracks, podcasts, or mobile telephone conversations. Users may desire small earphones. Users may also desire earphones that effectively block background ambient sounds from the user's outside environment.

Hearing aids, in-ear systems, and consumer listening devices typically utilize earphones that are engaged at least partially inside of the ear of the listener. Typical earphones have a driver mounted within a housing. Sound is conveyed from the output of the driver through a cylindrical sound port or a nozzle. A suitable ear device couples the sound port to the ear of the listener. As material such as earwax, dust, dirt, and debris may enter the sound port, they can potentially clog up the passageway that the sound passes through, blocking sound transmission and causing changes in frequency response, which can in turn affect sound quality. Additionally this may affect the internal components of the earphone rendering it inoperable. For example, outside materials can enter the sound port and alter the dampener.

BRIEF SUMMARY

One exemplary embodiment disclosed herein relates to a device for blocking materials from entering the sound port of an earphone, while simultaneously allowing sound to pass through unaffected. In one exemplary embodiment, a wax guard or barrier that is formed integral with a removable or replaceable ear sleeve assembly is disclosed.

In one exemplary embodiment an earphone having an elongated nozzle with a central opening adapted to transmit sound and a sleeve assembly is disclosed. The sleeve assembly can consist of a first opening and a second opening, a sleeve adapted for placement in the ear of a user, and a stem having an elongated body.

In another exemplary embodiment the stem body is tapered and has a first end and a second end. A barrier is mounted in the stem and is adapted to prevent materials from entering the central opening of the earphone nozzle. The stem is also adapted to receive the sleeve over its body, and the second opening in the stem is adapted to receive the nozzle therein. The sleeve can be cylindrical or tapered in shape, and the sleeve can be adapted to aid in blocking outside ambient noise. The stem, the barrier, and the sleeve can all be formed as an integral one-piece assembly, and the entire one-piece assembly can be adapted to be changed by the user.

In another exemplary embodiment the barrier is a grid and is formed of a woven material and comprises openings large enough to allow sound to pass through unaffected and small enough to prevent wax and debris to pass there through. The stem has a first opening and a second opening. The first opening can extend from the first end to the barrier, and the second opening can extend from the second opening to the barrier. The barrier can be placed nearer to the first end than to the second end of the stem.

These and other features of the present invention may best be understood with reference to the accompanying drawings and in the following detailed description of the invention.

DETAILED DESCRIPTION OF THE INVENTION

In this patent specification, the applicants use various headings only for convenience purposes. These headings are not intended in any way limit the scope of the disclosure.

Overall Earphone Assembly

FIG. 1depicts an earphone assembly10. The earphone assembly10may be a component or a sub-component of any in-ear listening device and is adapted to fit comfortably into a user's ear. The assembly10generally comprises an earphone100and a sleeve assembly200. The sleeve assembly200can comprise a sleeve250, a stem210, and a barrier or wax guard212mounted in the stem210. The sleeve250, the stem210, and the barrier212can be formed together as a one-piece construction to form the sleeve assembly200. However, it is contemplated that these components could be formed separately.

The earphone100may be formed integrally with or attached to any listening device by any method known in the art. The listening device may be used with a sound transmitting device, such as a wireless bodypack receiver, an MP3 player, Apple® iPhone or mobile telephone. As shown inFIG. 1, the earphone is formed with an earphone shell130, a shoulder120, and a nozzle110. The shell130forms a housing for receiving a driver and other internal components of the listening device. The shoulder120has an angled surface which abuts the stem210to act as an indicator that the nozzle110has been properly placed into the sleeve assembly200. The nozzle110directs the sound from the driver to the ear of the user.

The nozzle110can have an elongated shape for receiving the sleeve assembly200. The nozzle110has a central opening112extending there through and an open first nozzle end114and an open second nozzle end116for transmitting sound. The open second nozzle end116receives the sound from the driver and projects the sound through the central opening112out of the open first nozzle end114.

As shown inFIGS. 2 and 4, the stem210has a solid, yet flexible, elongated body and is formed with a first opening220and a second opening222. The first opening220extends from a first end216of the stem to the barrier212and allows sound to pass through. The second opening222extends from the second end218of the stem210to the barrier212and is shaped and adapted to receive the nozzle110. Because the barrier212is placed at or near the first end216of the stem210it can also act as an indicator to the user such that the user knows which end of the sleeve assembly200is placed onto the nozzle110.

As discussed below, the barriers212,312,412,512depicted inFIGS. 4-4Emay comprise a disc, grid, screen, cup, or matrix and may be formed of an insert-molded woven cloth or may be molded as one piece. The barriers212,312,412,512have openings214,314,414,514large enough to allow sound to pass through unaffected but small enough so as to not allow wax and debris to pass through. In other words, the openings can be formed of any suitable size to ensure that wax and debris are prevented from entering into the nozzle110while allowing sound to pass there through. As depicted in the Figures, the openings are formed as square shaped; however, the openings can be formed of any suitable shape.

As depicted inFIG. 2, in one embodiment, the barrier212can be formed with the stem210as one piece at the same time that the stem210is molded. In this embodiment both the barrier212and the stem210are formed together in a precision molding operation. The stem and barrier can be formed of thermoplastic urethane (TPU), polyvinyl chloride, or any suitable soft and flexible plastic material. Although any of the methods described herein could be used to manufacture the stem210, when the stem210and barrier212are formed as one piece, the barrier212may be less likely to separate from the stem210during use.

As depicted inFIG. 2A, the barrier212can alternatively be a separate component which is integrally molded into the stem210. The barrier212can formed of a cloth made of polyester thread, nylon thread, or any woven material. Alternatively, the barrier212can be formed of a stainless steel material. The barrier212may then be placed inside the mold during the molding of the stem210, such that it is molded into the inside of the stem210.

In another exemplary embodiment depicted inFIGS. 4A and 4B, the barrier312can be formed into a disc that is fastened into place over the stem210by any known method in the art, such as by gluing, heat sinking, and solvent bonding. The disc can be formed of the above listed materials, as well as other appropriate materials. Once formed the stem210is then pressed into a sleeve to form the sleeve assembly. The sleeve and bond between the barrier312and the stem210hold the barrier312into place on the stem210.

In another exemplary embodiment depicted inFIGS. 4C-4F, the barrier412can be formed into a cup, which again can be made of any of the above listed materials, as well as other appropriate materials. The barrier412can be fastened into place over the stem210by any known method known in the art, as discussed above. Again, the stem210is then pressed into a sleeve to form a sleeve assembly. Like in the embodiment discussed above, the sleeve and bond between the barrier412and the stem210hold the barrier412into place on the stem210.

In another exemplary embodiment, depicted inFIGS. 7 and 7A, the stem can be formed integral with the sleeve, and the sleeve can be formed of a silicone or a foam material. A separate barrier512with openings514can be formed of the materials listed above. The barrier512can be in-molded into the sleeve270to form a sleeve assembly400. Alternatively, the barrier512and the sleeve270can be molded as one piece and formed at the same time. The sleeve assembly400can be used in conjunction with the earphone assembly10shown inFIG. 1instead of sleeve assembly200.

As depicted inFIGS. 1-3, the barrier212can be formed longitudinally offset or displaced axially from the first end216and the second end218of the stem210, resulting in an annular lip or rim221that extends past the barrier212toward a user's ear when the earphone is in use. The annular lip221provides an attachment structure for receiving the barrier212if it is molded into the stem212for easier manufacturability. Additionally, as depicted inFIG. 2, the barrier212can be placed nearer to the first end than to the second end of the stem210. Although in the Figures the barrier212is depicted longitudinally offset from the first end216, the barrier212can be placed directly over the first opening220at the first end216as shown inFIGS. 4A and 4B.

As depicted inFIG. 1, the stem210can act as an intermediate component between the sleeve250and the nozzle110and provides structural rigidity and integrity to the sleeve assembly200. The stem210can be integrally molded to the sleeve250or can also be glued thereon to form the sleeve assembly200. The stem can be formed with a flange224, which contacts the sleeves250,260on one side and the earphone100on the other side. The flange224can be formed with an angular portion226which contacts a correspondingly angled shoulder120on the earphone100. The angular portion226on the flange224may allow for an easier assembly of the sleeve assembly200to the earphone100. The stem can be formed with a tapered body to ease the assembly of the sleeves250to the stem210to form the sleeve assembly200. The stem210can be formed such that it extends past the nozzle110at the first end of the earphone assembly10. This allows the barrier212to be placed in the first end of the stem210away from the nozzle110such that it does not contact the barrier212when assembled.

Sleeves

The sleeve may be formed of a compliant material to couple the earphone assembly10to the ear. The sleeve may be formed of a silicone material or a foam material. However, any suitable material may be used.

As shown inFIGS. 1,2, and5, the sleeve250has a first end252, a second end254, and a central opening256. The sleeve250can be tapered and can have greater tapering proximate the first end252. The tapering permits the sleeve250to be easily inserted into the ear of the user and permits the sleeve to form a seal in the user's ear such that the sleeve aids in preventing ambient noise from entering into the user's ear. In addition, the tapering proximate to the end of the sleeve250allows the sleeve to be compressed without blocking the opening in the first nozzle end114. However, other sleeve shapes can be implemented to provide passive noise reduction.

As depicted inFIGS. 3 and 6, the foam sleeve260has a first end262, a second end264, and a central opening266. The sleeve260is generally formed of a cylindrical shape; however, again other foam sleeve shapes are also contemplated. The foam sleeve260is adapted to provide a seal in the user's ear to aid in preventing ambient noise from entering into the user's ear. It is understood that the sleeve260can be used with the stem210as described herein and can be adapted to be used in conjunction with the earphone100.

The central openings256,266in the sleeves250,260are adapted to receive the stem210. The sleeves250,260can be either integrally molded with the stem210or separately adhered to the stem210. If the sleeves250,260are adhered to the stem, the flange224located on the stem can provide a stop to ensure proper placement of the sleeve onto the stem and provide more surface area for attachment. Additionally, the sleeve's length may be formed longer than the stem's length to prevent the stem from coming into direct contact with the ear, thus preventing discomfort and irritation in the ear.

Another sleeve embodiment is shown inFIGS. 7 and 7A. As depicted inFIGS. 7 and 7A, the sleeve is generally formed of a spherical shape. The sleeve270has a first end272, a second end274, and a central opening276. The stem310can be formed integral with the sleeve270at the same time in a molding operation to form the sleeve assembly400. The sleeve270is also adapted to provide a seal in the user's ear to aid in preventing ambient noise from entering into the user's ear. Again it is understood that the sleeve assembly400can be adapted to be used in conjunction with the earphone100.

The sleeve assemblies200,400can be held onto the nozzle110by a secure friction-fit through normal forces acting on the nozzle110and the stems210,310. However, any other methods of securing the sleeve assemblies200,400to the nozzle known in the art can also be used. A person of ordinary skill in the art would understand that both simple and complex connections are known in the art for connecting the sleeve assemblies to the nozzle, including, for example, friction/interference, barb, adhesive, ball and socket, bayonet, or screw thread.

In the embodiments shown in the Figures, the sleeve assemblies200,400are held in place over the nozzle110solely by a friction-fit between the inner surface of the stems210,310and the nozzle110, without use of adhesives. The user can place a new sleeve assembly200,400onto the nozzle110by aligning the nozzle110and the opening in the stem and by applying a force on the sleeve assembly200,400in an axial direction towards the earphone100. As sleeve assembly200,400is placed onto the nozzle110, the angled surface of the shoulder120abuts the stems210,310, which acts as an indicator that the nozzle110has been properly placed into the sleeve assembly200,400.

To remove the sleeve assembly200,400, while holding the earphone100, the user simply applies a force in the axial direction away from the earphone100, and the sleeve assembly200,400is permitted to slide off of the nozzle110. The user can then either replace the sleeve assembly200,400after cleaning it, or place a new sleeve assembly onto the nozzle110according to the steps above. The frictional forces are such that when a user pulls the sleeve assembly200,400out of his or her ear, the inner portion of the stems210,310remain engaged with the nozzle110, and the sleeve assembly200,400and earphone all come out of the user's ear together. This can be accomplished without the use of adhesives to connect the sleeve assembly200,400to the earphone100.

The exemplary embodiments discussed herein may help to provide a sleeve assembly200,400that may be easily changed by the user and keeps the nozzle110and its central opening112free of wax and other debris. The user may want to change the sleeve assembly as it may get damaged, soiled, uncomfortable, etc. over time. In this way, as the user changes ear sleeve assemblies for any reason they will also change the barriers or wax guards, replacing a potentially clogged wax guard with a new unclogged one. In addition, when the user identifies a problem due to wax or other debris clogging the openings256,266,276in the sleeves250,260,270respectively, they can easily solve the problem by simply changing the sleeve assembly200,400, which includes the barriers212,312. Thus, the sleeve assembly200,400may eliminate or reduce the amounts of earwax or other debris reaching the central opening112of the nozzle110, thereby reducing the need to clean the central opening112.

It will be recognized by those skilled in the art that the illustrated embodiments can be modified in arrangement and detail without departing from the scope of the present invention.