Flat earplug and package

A flat earplug and flat earplug package assembly is provided and a method of forming a flat earplug. The flat earplug includes a flat, rectangular foam sheet having a first surface and second surface, and adapted to be rolled up upon itself to form a coiled earplug for insertion into a user's ear. An inner coil is compressed to form a rigid coil when rolled up upon itself and an outer coil expands after the coiled earplug is inserted into the user's ear. The flat earplug package assembly includes a tray container for retaining the foam sheet therein and a wrapping for enclosing the flat earplug and tray container therein.

BACKGROUND

The present invention relates generally to an earplug. More specifically, the present disclosure relates to a flat earplug and a package therefore.

Earplugs are often worn in environments where it is desirable to have a reduction in the ambient or environmental noise levels. For example, it may be desirable to wear earplugs in a work environment where high noise levels are generated or in other situations such as concerts wherein high noise levels may also be encountered which could cause hearing damage. However, if the person does not have earplugs with them when they need them, they are of no use.

Also, earplugs typically have a substantially cylindrical or conical shape in order to fit comfortably within the ear canal of a user. However, the cylindrical or conical earplug may easily be compressed and take a set if not stored properly, which reduces the portability and flexibility of this style of earplug. Accordingly, there is a need in the art for a flat earplug package assembly that is more convenient to carry or have on one's person at all times, such as carried in a wallet or purse, is reusable, and the earplug is adjustable according to the anatomy of the user.

SUMMARY

Accordingly, the present disclosure relates to a flat earplug, a flat earplug package assembly, and a method of forming a flat earplug.

A flat earplug includes a flat, rectangular foam sheet having a first surface and second surface, and adapted to be rolled up upon itself to form a coiled earplug for insertion into a user's ear. The coiled earplug has at least one inner coil that is compressed when rolled up upon itself and an outer coil that expands after insertion into the user's ear to retain the earplug.

A flat earplug package assembly includes a flat, rectangular foam sheet adapted to be rolled up upon itself to form a coiled earplug for insertion into a user's ear. At least one inner coil is compressed when the foam sheet is rolled up upon itself to form the coiled earplug and an outer coil that expands after the earplug is inserted into the user's ear. The flat earplug package assembly further includes a tray container for retaining the foam sheet therein and a wrapping for enclosing the flat earplug and tray container therein.

The method of forming a flat earplug includes the steps of providing a foam sheet having a first surface and a second surface, and a predetermined thickness; removing a backing from a foam sheet having a first end and a second end; rolling the foam sheet upon itself from the first end of the foam sheet to the second end of the foam sheet to form a substantially cylindrically shaped coiled earplug; adjusting a diameter of each coil of the earplug by compressing the foam sheet as it is rolled upon itself; and placing the coiled earplug into an ear canal of a user's ear, such that the coiled earplug expands and is retained within the user's ear. The method further includes the steps of removing the coiled earplug from the user's ear and unrolling the coiled earplug back into the flat earplug; and placing the flat earplug back into the tray container for later reuse.

One advantage of the present disclosure is that the flat earplug package assembly is provided that is portable, more compact and allows for easier storing, such as in a wallet. Another advantage of the present disclosure is that the size of the flat earplug is customizable to the user by adjusting the number of coils. Still another advantage of the present disclosure is that the flat earplug quickly returns to its nominal thickness after removal from the package. A further advantage of the present disclosure is that the flat earplug is reusable and is protected within the package assembly. Still a further advantage of the present disclosure is that the flat earplug package distributes forces on the earplug in a uniform manner while in contained in the package. Yet a further advantage of the present disclosure is that the flat earplug can be die cut from a piece of foam material. Still yet a further advantage of the present disclosure is that the flat earplug is cost effective to manufacture and reduces material scrappages.

Other features and advantages of the present disclosure will be readily appreciated, as the same becomes better understood after reading the subsequent description taken in conjunction with the accompanying drawings.

DETAILED DESCRIPTION

Referring toFIGS. 1-11, a flat earplug assembly is generally shown at10. The flat earplug12has a substantially rectangular shape and is defined by ends14and sides16. The flat earplug12is generally flat in cross section. The flat earplug12may be mounted or affixed to an optional backing or release sheet18, as shown inFIG. 2to form the flat earplug assembly10. The flat earplug12may be inserted into an ear canal of a user's ear.

The flat earplug12is formed from a sheet of foam material13, such as an open cell foam material. Referring toFIG. 3, the foam sheet13has a first surface20and a second surface22, and an open cell foam layer24disposed therebetween. An example of a foam material includes urethane, polyvinylchloride, etc. Another example of a material used to make the foam sheet is a Food and Drug Administration (FDA) approved foam. The foam sheet13is manufactured utilizing methods and techniques typically known by those of ordinary skill in the art. The flat earplugs12may be fabricated from a foam sheet13having a perforation or cut that divides the foam sheet13, such as into two halves. When the foam sheet is13separated or pulled apart along the perforation or cut, two halves are created which now provide two separate flat earplugs12that may be used for both the left and right ear of the user, as shown inFIGS. 5 through 8.

The foam sheet13can be manufactured in such a way so as to provide both of the surfaces20and22of the flat earplug12with a generally cellular texture as shown inFIG. 1. Alternatively, the foam sheet13can be constructed so as to provide either surface20or surface22with a substantially smooth skin or finished surface, as shown inFIG. 3. The smooth or finished surface has a more closed cellular structure than that of the inner layer.FIG. 4illustrates a flat ear plug12formed from a foam sheet13whereby both surfaces20,22include a substantially smooth surface or skin disposed thereon. For example, the foam sheet13may be die cut from a larger piece of foam material, and the foam material may have a first or second surface that is “skinned”.

In an example of a foam sheet13whereby at least one surface20,22includes a skin thereon, the skin preferably provides a semi-adhesive, adhesive, or tacky property to the surface. Therefore, when the flat earplug12is rolled upon itself to form the coiled earplug, the skin associated with either surface20, surface22, or both surfaces, allows the surfaces20,22to partially adhere to one another as coils are being formed and/or resist sliding or movement therebetween. The semi-adhesive property can be intrinsic to the skin formed on the surface20, surface22, or both surfaces, or can be an adhesive coating applied to either surface20, surface22, or both. The adhesive may be a weak, non-permanent adhesive, such as an FDA approved adhesive.

The skin disposed on either surface20, surface22, or both, provides the earplug10with a longitudinally extending rigidity along the line L-L as shown inFIG. 9. That is, when the flat earplug10is rolled into a coil, the first coil23is compressed to form an inner core that may be rigid that facilitates in insertion of the coiled earplug15. Each successive coil may be under less compression than the first coil23, and may also facilitate insertion and expand after insertion. The last or outer coil25may be compressible before insertion and expandable after insertion to custom fit the coiled earplug15according to the particular anatomy of the user. The skin disposed on either surface20, surface22or both, further imparts the earplug10with the ability to resist compression and/or deformation in the direction along the line defined by L-L. This rigidity and/or resistance to compression along the line L-L, allows the earplug10to be more easily inserted into the ear of the user, without flattening out during insertion.

The substantially semi-adhesive properties of the foam sheet13and/or of the skin on either surface20and/or surface22also provides the user of the earplug10with the ability to adjust both the size and/or comfort of the earplug10. Because of the semi-adhesive property of the foam used to make the foam sheet13and/or the adhesive properties of the surfaces20,22, the user of the earplug10can adjust the overall size or diameter of the earplug by varying the tightness by which they spirally roll the foam sheet13from the first end14to the opposite end14, and the number and size of coils, with the inner coil23being the most compressed and the outer coil25the least compressed. In addition, the adhesive characteristic of the surface layer enhances the rigidity of the flat earplug12, and assists in retaining a coiled shape of the flat earplug12when inserted into a user's ear in a manner to be described. Further, the adhesive characteristic enhances reusability of the flat earplug12, or readjustment of the flat earplug12or the like in use to accommodate the individual user's ear canal shape and size.

The flat earplug12may be secured to a backing or release sheet18. The backing or release sheet18can be any suitable material, such as paper, coated paper, cardboard, plastic foil, or the like. In addition, the backing or release sheet18may incorporate information, such as instructions, warnings, advertising, logos, images, or other indicia, or the like, printed thereon.

Other examples of a flat earplug12are shown inFIGS. 12 through 21. Like reference number have like numbers increased by 100. The sides16of the foam sheet13can have various profiles to accommodate additional comfort and/or fit. Referring toFIGS. 12 and 13, the foam sheet112, alternatively can include a slight taper from one side116to the other side116in order to facilitate the generation of a predetermined shape, such as a “cone-shaped” earplug110upon rolling of the foam sheet113. The taper may be gradual, tapered profile from one side116to the other side116wherein both sides116have a straight profile and the length of one side116is shorter than the other side116. As shown inFIGS. 14 and 15, the foam sheet213may have at least one side216that includes a rounded profile. Referring toFIG. 16 through 21, the foam sheet313may have at least one side316that includes a beveled profile. Alternatively, both sides316may include a beveled profile. As shown inFIGS. 1 through 8, both sides16can have a straight profile.

Referring toFIG. 22, a flat earplug package assembly24is illustrated. The flat earplug package assembly24may include the flat earplug12, the backing or release sheet18, the earplug tray container26, or an outer cover or wrapping. The flat earplug12is placed into the earplug tray container26which then may be placed within a protective wrapping28to complete the package assembly24.

Referring toFIGS. 23 through 24, the earplug tray container26is illustrated. The tray container26includes a base wall29and side walls30extending upwardly from an edge of the base wall29. The base wall29may be a solid wall, or it may have a centrally located opening. The tray container26may be fabricated from a material (e.g., plastic, paper, cut piece of extruded plastic, recycled or the like) and is constructed to generally have the same size and shape of a pair of flat earplugs12. In an example, the flat earplug12may be placed snugly within the earplug tray container26.

The side walls30of the earplug tray container26may have a predetermined height. For example, the predetermined height may be slightly less than the height of sides14,16of the flat earplug12, so that a predetermined depth of the flat earplug12is above the walls30, as shown inFIG. 25at27. For example, the height of the walls30may be up to 25% less than the corresponding depth of the flat earplug12and card (if utilized). The flat earplug12may be slightly compressed when placed within a wallet for example, but the walls30ensure that the flat earplug12is not compressed over a predetermined amount so that the flat earplug12quickly returns to it's original dimensions after removal from the tray26. For example, if the foam material is compressed by more than 25%, the material may acquire a significant set over time. In another example, if the compression of the material is less than 25%, the set may be less than 4%. If the material acquires too great of set, the elasticity of the material and its ability to recover over time is influenced. (i.e., flat earplug's ability to compress and decompress during use). The flat earplug12may be compressed slightly due to the lower height of the walls30, however, this slight compression may compensate for any dimensional tolerances inherent in the foam material. The walls30of the earplug tray container26may also have a plurality of ribs32which provide additional rigidity to the walls30of the earplug tray container26and thereby further prevent excessive compression of the flat earplug12. Some compression of the flat earplug12can occur when the flat ear plug assembly24is stored within another object, such as when placed in a wallet or the like. However, the resiliency of the foam returns the flat ear plug12back to it's original size and shape.

The protective wrapping28may be manufactured from any suitable material (e.g., plastic, paper, etc.) and has dimensions that are preferably slightly larger than the foam sheet12, optional backing or release sheet18, and the earplug tray container26so that these items may be placed snugly therein and thereby form a relatively small and compact package assembly24. The protective wrapping28protects the flat earplug10from damage, from the elements (e.g., moisture, etc.) and keeps the flat earplug12clean, sterile and free of debris (e.g., dust, etc.).

Referring now toFIG. 26, a flow chart of the method of using the flat earplug assembly12is shown. The first step34, includes providing a foam earplug assembly10having a pair of foam earplugs12positioned on a sheet18and placed within a tray26. For example, by placing the flat earplug12with the card opposite the tray base wall29, the flat earplug12is further protected since any forces on the ear plug package24are distributed more evenly. In a second step36the flat earplug12is removed from the tray26and from the backing or release sheet18.

In a third step38, the foam sheet13is rolled or coiled into a spiral from the first end14to the opposite end14, as shown inFIGS. 9 and 10. The first coil23is compressed to form a rigid inner core that assists in retention of the earplug shape and insertion in the user's ear. The middle and outer coils may also assist in retaining the longitudinal shape of the earplug during insertion, due to the rigid frame formed by the skin to skin contact of the foam material. In the fourth step40, the diameter of the coiled earplug15may be adjusted depending on the size and shape of the user's ear canal, by the amount of compression used in forming each coil as the foam sheet13is rolled upon itself into a spiral. Upon rolling of the foam sheet13from the first end14to the opposite end14, foam sheet13becomes a substantially cylindrically shaped coiled earplug15, as shown inFIG. 9. The outer coil25is compressible before, and expandable after insertion. The coils may also be further compressed during insertion. At least one end14can be tapered in order to provide a smooth transition when the foam sheet13is rolled in a spiral manner onto itself to impart additional comfort to the user of the earplug12. In addition, the finished surface20,22can enhance comfort of the earplug in the user's ear.

In a fifth step42, the compressed coiled earplug15is placed into an ear canal of a user's ear, such that the coiled earplug15compresses and expands according to the size and shape of the user's ear in order to be retained within the user's ear. For example, the user grasps the upper end of the ear, and gently pulls the ear in an upwardly direction. The coiled earplug15is placed in the ear such that the coils are oriented in a coiled direction, such as a clockwise direction. The user turns or spins the coiled earplug15in the coiled or clockwise direction of this example while inserting the earplug15, in order to locate the earplug within the ear canal. The outer coil25may compress and then expand to fit the ear canal. Some of the middle coils may also compress and then expand, depending on how tightly they were compressed and the anatomy of the user's ear. In a sixth step44, the coiled earplug15is removed from the user's ear and unrolled. In a seventh step46, the now flat earplug12may be placed back on the card18and/or placed back into the tray container26for later reuse.