An insert assembly is provided having a sleeve configured to receive an insert. The sleeve includes an undercut feature resting on a mating surface on the outside of the insert. The insert having a concentric rib on its outer diameter. The mating surface provides friction between the sleeve and the insert by at least partial encapsulation of the sleeve using the undercut feature, retaining the insert within the sleeve. The mating surface includes a multi-level surface that interlocks the sleeve and the insert.

BACKGROUND

Traditional earplug style headphones have earbuds that slide over a hard plastic post attached to the earbud's body. This post usually contains a concentric rib that interfaces with the elastic ear tip. Each elastic ear tip has the same mating feature, so all sizes are retained consistently on the plastic earbud. The portion of the earbud that contacts the ear can cause occlusion in the user's ear, distorting sound and providing an uncomfortable experience. Retention is also an issue because the ear canal is often the sole mating surface for these devices. The retention scheme utilized in previous in-ear headsets exerts a large amount of force on pressure points in the ear canal, making them uncomfortable.

The fit achieved by in-ear monitors requires that each headset be custom-made, adding cost and time to the production process. These are not mass producible. Aviation and consumer headsets that do not use the earplug style tips use a flexible interface over a hard insert. This variation of the ear plug design can lead to unwanted occlusion and pressure points throughout the ear.

There is a need for an earbud that provides reliable retention while maintaining a low profile.

SUMMARY

According to one aspect of the subject matter described in this disclosure, an insert assembly is provided. The insert assembly includes a sleeve configured to receive an insert. The sleeve includes an undercut feature resting on a mating surface on the outside of the insert. The insert having a concentric rib on its outer diameter. The mating surface provides friction between the sleeve and the insert by at least partial encapsulation of the sleeve using the undercut feature, retaining the insert within the sleeve. The mating surface includes a multi-level surface that interlocks the sleeve and the insert.

According to another aspect of the subject matter described in this disclosure, an earbud is provided. The earbud includes at least one interchangeable sleeve configured to be stretched over an insert providing consistent fits for multiple ear sizes. The at least one interchangeable sleeve has at least a first protruding section for retention of the insert in an ear of a user.

According to another aspect of the subject matter described in this disclosure, a method for forming an earbud is provided. The method includes providing a sleeve configured to receive an insert. The sleeve has an undercut feature resting on a mating surface on the outside of the insert. The insert includes a concentric rib on its outer diameter. Also, the method includes delivering, using the mating surface, friction between the sleeve and the insert. Moreover, the method includes retaining the insert within the sleeve by at least partially encapsulating the sleeve by the undercut feature. The mating surface comprises a multi-level surface that interlocks the sleeve and the insert.

Additional features and advantages of the present disclosure is described in, and will be apparent from, the detailed description of this disclosure.

DETAILED DESCRIPTION

This disclosure is directed to an intra-aural earbud for a hard insert. The intra-aural earbud is designed to be a well-retained but replaceable earbud on top of a hard insert. Moreover, the intra-aural earbud provides a comfortable interface between a hard insert and the user. The intra-aural earbud is configured to allow the user to apply the intra-aural earbud to the hard insert using a sleeve arrangement.

FIG.1A-4Bare schematic diagrams of a hard insert100, in accordance with some embodiments.FIG.1Ashows hard insert100having a hard/rugged plastic outer surface102forming a hard insert to protect its internal components. The hard insert100has a hardness of at least 15 SHORE D. The internal components of hard insert100include electronics (i.e., microprocessors, receivers/transmitters, etc.), a speaker, a microphone, a battery, or the like positioned at fixed locations in hard insert100. The hard insert100, as shown, has an ear canal portion104designed to rest within the ear canal of a user. Moreover, the hard insert100includes a hard plastic post106configured to optionally receive a support mechanism to allow a user to comfortably wear or position hard insert100on a user's ear.

In some embodiments, the support mechanism is an ear hook with a plastically deformable inner core allowing a user to form the ear hook to fit his/her ear. This ear hook can also house electronics such as bone conduction sensors.

FIG.1Bis a schematic diagram of the bottom view of hard insert100, in accordance with some embodiments. The hard insert100includes several concentric ribs114A-114B on the outer diameter of hard insert100, and shelf feature114C configured to be a concentric face of hard insert100.

FIG.2A-2Care schematic diagrams of an intra-aural earbud200, in accordance with some embodiments. In particular,FIG.2Ashows intra-aural earbud200includes a sleeve202configured to receive hard insert100. The sleeve202uses an undercut feature208to wrap around hard insert100. Features in hard insert100keep the sleeve flush with the outer plastic face of hard insert100. The elasticity of sleeve202is such that it is allowed to be stretched around hard insert100. The rear face of hard insert100that protrudes outside the user's ear has shelf feature114C and concentric rib114A to catch the undercut feature208on sleeve202. The undercut feature208of sleeve200is stretched around hard insert100as sleeve202is being installed.

When hard insert100has been fully installed in sleeve202, the undercut feature208rests on its mating flat surface208on the outside of hard insert100. Flat surface208provides friction between hard insert100and sleeve202that, aided by the encapsulation of hard insert100by undercut feature208, retains hard insert100within sleeve202.FIG.2Bshows a multi-level mating surface210being configured as a puzzle piece type interface that interlocks sleeve202and hard insert100via concentric ribs114B and114C. Between hard insert100and sleeve202is an open space206used for positioning hard insert100.

FIG.2Cis a schematic diagram of a front view of intra-aural earbud200, in accordance with some embodiments. The intra-aural earbud200includes an ear canal portion226designed to rest within the ear canal of a user. The intra-aural earbud200also has a concha bowl portion228and a concha cymba portion230, designed to rest against the concha bowl and concha cymba, respectively, of a user's ear. In some particular exemplary embodiments, the ear canal portion226has a length in the range between 8-12 mm. In some exemplary embodiments, this range may be larger. Normally, the ear canal portion226is between 8-10 mm in length in a standard size. The ear canal portion226is sized to receive ear canal portion104of hard insert100.

The concha cymba portion230can also be designed to maximize grip strength. Generally, a softer concha cymba portion230improves its grip once inserted into the ear, but higher compressibility results in a better fit. Concha cymba portion230does not provide the main forces that retain the assembly in the user's ear. Most retention is achieved through the combination of ear canal portion226, sleeve202, concha bowl portion228, and concha cymba portion230. The concha bowl portion228can be configured for an environment where maximizing grip strength is desired. Again, materials of different stiffness can be used to conform to idiosyncrasies of a variety of ear anatomies.

The intra-aural earbud200is designed to be interchangeable, ensuring fit for everyone. Sleeve202is preferably made with low durometer silicone coupled with a hard insert to avoid pressure points. In some embodiments, materials that perform similarly to silicone may be used. In some exemplary embodiments, sleeve202is made with high durometer silicone.

FIG.3is a schematic diagram of a cross-sectional view of a sleeve300used in an intra-aural earbud, in accordance with some embodiments. The sleeve300is substantially similar to sleeve202ofFIG.2. In this case, the sleeve300includes an outer surface304and concentric cavities302A-302C. The concentric cavities302A,302B, and302C interface with concentric ribs114A and114B, and shelf feature114C of hard insert100, respectively. Sleeve300is stretched, so concentric ribs114A and114B are positioned in concentric cavities302A and302B. Shelf feature114C is positioned in concentric cavity302C, which is used to catch the undercut feature of sleeve300. This interlocks sleeve300and hard insert100and maintains sleeve retention.

FIG.4is a flowgraph of a process400for forming an earbud, in accordance with some embodiment. Process400includes providing a sleeve (such as sleeve200or300) configured to receive an insert (such as hard insert100)(Step302). The insert has a concentric rib (such as concentric rib114A.114B, or114C) on its outer diameter. The sleeve includes an undercut feature (such as undercut206) resting on a mating surface (such as mating flat surface208) outside the insert. Process400includes delivering, using the mating surface, friction between the sleeve and the insert (Step304). Process400includes retaining the insert within the sleeve by at least partially encapsulating the sleeve with the undercut feature (Step306). The mating surface includes a multi-level surface (such as multi-level mating surface210) that interlocks the sleeve and the insert, using the rib and the undercut feature.

The disclosure described an intra-aural earbud having a sleeve used in conjunction with a hard insert. In some exemplary embodiments, the intra-aural earbud includes a low-durometer silicone sleeve that avoids pressure points. The advantages of the intra-aural earbud include reliable retention of a variety of sleeves (silicone ear interface) that fill the volume of the concha and the auditory canal while maintaining a low profile. Also, the sleeves are retained to ensure they remain on the hard insert. Moreover, the intra-aural earbud provides the user with a more comfortable experience. The flexibility of the sleeve offers a fit comparable to studio monitors without the need for custom forming. In addition, the sleeves are interchangeable to ensure fit for all people.

Reference in the specification to “one implementation” or “an implementation” means that a particular feature, structure, or characteristic described in connection with the implementation is included in at least one implementation of the disclosure. The appearances of the phrase “in one implementation,” “in some implementations,” “in one instance,” “in some instances,” “in one case,” “in some cases,” “in some exemplary embodiments,” “in one embodiment,” or “in some embodiments” in various places in the specification are not necessarily all referring to the same implementation or embodiment.

Finally, the above descriptions of the implementations of the present disclosure have been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the present disclosure to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. It is intended that the scope of the present disclosure be limited not by this detailed description, but rather by the claims of this application. As will be understood by those familiar with the art, the present disclosure may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. Accordingly, the present disclosure is intended to be illustrative, but not limiting, of the scope of the present disclosure, which is set forth in the following claims.