# Patent

## Title
Custom in-ear monitor

## Abstract

An in-ear monitor that can be customized for particular applications and individuals includes a housing formed from a body and a cover. A dynamic driver is mounted in a cavity in the housing on an angled mounted flange. The dynamic driver is acoustically coupled to a trumpet-shaped sound collector. The trumpet-shaped sound collector is coupled to a main sound bore that exits an opening in a nozzle portion of the body that is inserted into the ear canal of a user. An ambient sound port collects ambient sound and couples it to the sound bore. An additional bass port increases the bass response of the monitor. Ear impressions are used to customize the body of the monitor to the ear of a user and the location of the bass and ambient sound ports can be altered for different applications.

## Background
CROSS-REFERENCES TO RELATED APPLICATIONS
The present Utility patent application is based upon and claims priority from U.S. Provisional Patent Application No. 61/534,404 filed Sep. 14, 2011.


STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
REFERENCE TO SEQUENCE LISTING OR COMPUTER PROGRAM LISTING APPENDIX
Not Applicable.
BACKGROUND OF THE INVENTION
Musicians, performers and the like that need to hear themselves and other members of a band or performers in order to stay in-time and/or in-tune are required to utilize a methodology to hear one another called monitoring. Historically open speakers called floor wedges have been used to provide a combined mix of the performers voices, instruments and/or music tracks in order for the performers to hear other pertinent audio during the performance.
Some years ago legacy hearing aid in-ear custom molded monitors were introduced into the market. These custom in-ear monitors took the place of the floor wedges. The custom in-ear monitors substantially reduced the amount of equipment needed for the performers, lowered overall stage volume and reduced risk of hearing damage from performers by allowing the overall monitoring level to be lower.
Since the advent of custom in-ear monitors the process for manufacturing them and the resulting product has not changed very much. This can be attributed to limited types of speaker technologies, legacy manufacturing methods utilized and materials and parts available for assembly. Although these methods and materials work, they fall short in many areas. These areas include: low frequency performance, sweat abatement into the inside, cerumen vapor intrusion, comfortable yet sealed canal lengths, ruggedization, reparability, digital manufacturing methodologies, precision internal parts, use of hybrid driver configurations, tunability, placement and sound bore diameter and length calculation for optimal performance.
With this the need exists for a better design which answers all of these shortcomings. A better custom in-ear monitor needed to be designed to better serve those who utilize them for their very livelihood.
BRIEF SUMMARY OF THE INVENTION
An embodiment of the present invention is directed toward an in-ear monitor that is contained within a housing having a cover and a body. A trumpet-shaped sound collector is positioned in the housing. A main sound bore is acoustically coupled to the trumpet-shaped sound collector. A nozzle having a nozzle opening in the body is acoustically coupled to the sound bore. The nozzle includes a recessed channel and a sealing o-ring positioned on a tip of the nozzle that function as an ear canal seal. A bass port is acoustically coupled to the nozzle opening. An ambient port is also preferably acoustically coupled to the nozzle opening. A dynamic driver, such as a coaxial speaker or balanced armature receiver, is coupled to the trumpet shaped sound collector. The bass port preferably has a bass port valve that selectively restricts a sound flow through the bass port. The ambient port preferably includes an ambient port valve that selectively restricts a sound flow through the ambient port. A balanced armature receiver is acoustically coupled to the main sound bore. The balanced armature receiver is most preferably positioned directly inside the main sound bore.
Another embodiment of the present invention is directed toward a method of constructing a custom in-ear monitor. The method begins with the obtaining of an ear impression from a customer. A digital body model of a monitor body is created based on the ear impression. The digital model is then manipulated to remove surface abnormalities. Component templates are positioned in the digital body model. A driver is preferably mounted in the body and a balanced armature receiver is preferably positioned in a main sound bore of the in-ear monitor. The loft of a speaker mount in the in-ear monitor is adjusted to accommodate the selected driver. Valve adjustments are provided for a bass sound port and an ambient sound port of the in-ear monitor. The component templates are extracted from the digital body model. A cover template is fitted onto an upper surface of the digital body model. The in-ear monitor is then manufactured based upon the modified digital body model.



BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a three-dimensional drawing of an in-ear monitor constructed in accordance with an embodiment of the present invention;
FIG. 2 is an illustration of a preferred cover for an in-ear monitor constructed in accordance with an embodiment of the present invention;
FIG. 3 is an illustration of a shaped cavity constructed in a cover for an in-ear monitor in accordance with an embodiment of the present invention;
FIG. 4 is an illustration of a solid model insert used to expedite custom in-ear-monitor cover designs in accordance with an embodiment of the present invention;
FIGS. 5(A-D) are illustrations of alternative ambient port configurations in accordance with the present invention;
FIGS. 6(A-C) are illustrations of alternative bass port placements in accordance with the present invention;
FIG. 7 is an illustration of a coaxial speaker for use in an embodiment of the present invention;
FIG. 8 is an illustration of a lofted cut out area or angled mounting flange in the in-ear monitor into which a driver is inserted in accordance with an embodiment of the invention;
FIGS. 9(A) and 9(B) are illustrations of balanced armature receiver placements in accordance with embodiments of the present invention;
FIG. 10 is an illustration of an enhanced ear canal seal in accordance with an embodiment of the invention; and
FIG. 11 is a flow chart of a preferred method of constructing a custom fitted in-ear monitor in accordance with the present invention.



DETAILED DESCRIPTION OF THE INVENTION
The present invention is directed toward an in-ear monitor that can be customized for particular applications and individuals. The monitor includes a housing formed from a body and a cover. A dynamic driver is mounted in a cavity in the housing on an angled mounting flange. The dynamic driver is acoustically coupled to a trumpet-shaped sound collector. The trumpet-shaped sound collector is coupled to a main sound bore that exits an opening in a nozzle portion of the body that is inserted into the ear canal of a user. An ambient sound port collects ambient sound and couples it to the sound bore. An additional bass port increases the bass response of the monitor. Ear impressions are used to customize the body of the monitor to the ear of a user and the location of the bass and ambient sound ports can be altered for different applications.
Referring now to FIG. 1, a three-dimensional drawing of an in-ear monitor constructed in accordance with an embodiment of the present invention is shown. The monitor 2 includes a cover 4 that mates with a body 6 to form an outer shell for the monitor. The cover 4 has openings 8 for attachment screws and a recessed connector 10 that receives a cable connector. The body 6 includes a nozzle 12 with a nozzle opening 14 that is inserted into the ear of a user. An ear canal seal or o-ring groove 16 that receives an o-ring, as discussed in more detail below, is provided around the nozzle opening 14 help seal the nozzle 12 in the ear of the user. The body 6 also includes an external opening 18 for the ambient sound port 20 and an external opening for the bass sound port 22.
The in-ear monitor 2 preferably has a main smooth-flowing sound bore 24 acoustically coupled to a trumpet-shaped sound collector 26 that smoothly channels sound down the main sound bore 24 into the ear of the user. This configuration does not disturb the natural flow of sound from a dynamic driver 28 down the main sound bore 24 and creates a smooth path to the ear through the nozzle 12. An angled driver flange 32 is used to mate the sound collector 26 with the dynamic driver or speaker 28. As discussed in more detail herein, an ambient port valve 30 is used to selectively restrict the ambient sound port 20 and a bass port valve 34 is used to selectively restrict the bass sound port 22. Needle valves are preferably used to adjust the porting of the bass and ambient sound channels. However, any small valve design such as a slide valve, ball valve or butterfly valve can be utilized to adjust the porting.
The in-ear monitor 2 has an enlarged main sound bore 24 that is preferably 3-6 mm in diameter. The large size of the sound bore 24 reduces any effects of sweat which can clog standard sound bore tubes. It also allows for easy cleaning with a Q-tip to remove ear wax buildup.
Referring now to FIG. 2, an illustration of a preferred cover 40 design for an in-ear monitor constructed in accordance with an embodiment of the present invention is shown. The preferred cover 40 has an 11 degree draft, + or −5 degrees, to allow the speaker to fit within the concha bowl of the ear. This also allows the cover 40 to follow basic contour of the perimeter of the ear without causing excessive pressure on the edge of the helix and concha. The contoured shaped cover 40 has a bulge 42 that allows the speaker magnet to clear the cover surface and increases the air volume on the back side of speaker.
The connector 43 for the in-ear monitor cable is recessed into the cover 40 for added comfort and strength. The recessed connector 43 is used to connect the ear monitor to a wired or wireless belt pack receiver, or other amplified audio source. Recessing the connector 43, reduces strains placed on the connector that result from pulling on the cable attached to the connector.
The cover 40 is preferably constructed so that a recessed logo can be engraved in the outer surface of the cover. This gives a dimensional look to any text or logo added to the cover and can be easily painted to enhance the visual appearance of the cover. The cover 40 can be made of almost any material such as carbon fiber, wood, ivory, mother of pearl, etc.
The cover 40 can also be plated with metals such as chrome, gold, black rhodium, etc. The cover 40 is preferably attached with recessed, stainless, self-tapping T-3 torx bit screws. These screws thread themselves into the 1.1 mm×6 mm holes 45 on the body to attach the cover 40 and allow its removal when needed for repair or cleaning. While torx bit screws are preferred, any type of suitable of screw can be used.
As shown in FIG. 3, the inside surface of the cover 40 of the in-ear monitor preferably includes a shaped cavity 44. The shaped cavity 44 adds significant air volume to the back side of speaker which increases the low frequency response of the in-ear monitor speaker.
As shown in FIG. 4, a solid model insert 50 may be used to expedite custom monitor designs. Utilizing digital models 50 of the parts that will fit into the shell allows you to both precisely fit them into the model of each person's ear with high accuracy, which cannot be achieved any other way, and use them to form cavities corresponding to the dimensions of the inserted parts models. Once the solid model parts 50 are placed in the solid model of the ear they can then be extracted. This extracting causes a negative cavity of each part to be formed. These resulting areas can then be further worked utilizing CAD software to ensure everything fits together, the speakers can be inserted in the 3D printed version, perfect fit into the ear, threads formed for valves, and accurate porting achieved. Additionally utilizing this method allows for precise air volume calculation and modeling as well as sound bore placement and size for each individuals ear. Thus, using an add-in cad template for non-custom mechanical parts enables faster design of the monitor in the 3D cad environment.
As discussed above an ambient sound port is positioned in the body. The ambient sound port 60 can be positioned in the body 62 in one of two different manners. As shown in FIG. 5(A), the ambient port 60 can be routed from the ambient port opening through an ambient valve 66 to an opening in the main sound bore 68. Alternatively, as shown in FIG. 5(B), the ambient port 60 can be routed from the ambient port opening 64 through the ambient valve 66 to an opening 69 near the tip of the canal opening. This arrangement provides for increased bass response.
The ambient port opening 64 can also be positioned in two different locations. As shown in FIG. 5(C), positioning the ambient port opening 64 at the helix of the ear accommodates different ear shapes and allows for directional hearing or hearing localization such that the user can hear in a more normal manner. Alternatively, as shown in FIG. 5(D), the ambient port opening 64 may be placed between the tragus and helix behind the connector or wire for the in-ear monitor.
As shown in FIGS. 6(A-C), the exit for the bass port 70 in the in-ear monitor can be positioned in one of three different preferred locations. In the first position, FIG. 6(A), the bass port 70 is routed from inside the rear speaker air volume through the valve area into the main sound bore 72. In the second position, the bass port 70 is routed from inside the rear speaker air volume through the valve area to an external vent 74 located on the outside of the shell 76. The external vent 74 can be placed anywhere that allows it to be open and not closed off by the ear. In the third position, the bass port 70 is vented from the backside of speaker air volume through the valve area to an external vent opening 74 positioned at tip of the canal opening.
As shown in FIG. 7, the in-ear monitor if the present invention preferably utilizes a coaxial, adjustable speaker 80 for a flatter frequency response. The speaker has dual dynamic drivers 82 and 84 that are driven by an amplified sound source. The larger driver 82 is for bass response while the smaller 84 is for mid and high range frequencies. Multiple smaller drivers can be utilized in connection with the coaxial speaker for enhanced response. An IPEX connector or solder pads can be used for wiring to the external connector. Crossovers or filters are used to reduce undesirable low and/or high frequencies in the inputs to the drivers. A potentiometer is preferably used to tune in the amount of speaker output.
As shown in FIG. 8, a lofted cut out area or angled mounting flange 88 is provided in the shell into which the speaker 90 is inserted. The lofted cut out area 88 allows for the speaker 90 to be inserted into the mounting area at an acute angle. The amount of loft is selected such that the custom position of the speaker 90 can be mated with the flat plane of the top of the body 92.
The in-ear monitor preferably makes hybrid use of both dynamic drivers and balanced armature receivers for added high frequency response. As shown in FIG. 9(A), the balanced armature receiver 100 can be connected with sound tubes 102 to the main sound bore 104. Placement of the balanced armature receiver 100 can be made anywhere it will fit inside the outer shell and then ported into the main audio bore at any point that works for a particular application. In addition, as shown in FIG. 9(B), a balanced armature receiver 100 can be positioned in the center of the main audio bore 104. Positioning the balanced armature receiver 100 directly in the main sound bore 104 can greatly enhance the directed performance of the balanced armature speaker. Any number of balanced armature receivers can be added to the in-ear monitor to augment the frequency response.
As shown in FIG. 10, the in-ear monitor of the present invention utilizes an enhanced canal seal 110. The canal seal 110 is preferably 1 mm diameter an o-ring 112 that is inserted into a canal-shaped groove 114 that is 0.6 mm×1 mm on the tip of the nozzle 116 to provide an approximately 0.3-0.5 mm sealing surface in ear canal. These preferred dimensions can be changed to satisfy each individuals requirements for comfort and fit. This extra o-ring seal 110 on the nozzle 116 allows the portion of the monitor inserted into the canal to be shorter which makes the monitor more comfortable to wear.
As shown in FIG. 11, a preferred method of constructing a custom fitted in-ear monitor begins in step 120 with the taking of ear impressions from a customer. The ear impressions are then inserted into a three dimensional scanner to create a digital model of the ear impressions in step 122. In step 124, software is used to manipulate the digital model to remove surface abnormalities. Three dimensional cad design software is used in step 126 to position a custom templates into the body of the monitor. The loft of the speaker mount is adjusted in step 128 so that the speaker template can be fitted into the body. The templates are then extracted in step 130 from the body of the digital model. In step 132, a cover is then designed based on the outline of the flat plane at the top of the body. The digital model can then be modified and an outer shell created from the digitized model using three-dimensional printing or other manufacturing techniques in step 134.
Although there have been described particular embodiments of the present invention of a new and useful IN-EAR MONITOR, it is not intended that such references be construed as limitations upon the scope of this invention except as set forth in the following claims.

## Claims

1. An in-ear monitor, said in-ear monitor comprising:
a housing having a cover and a body;
a trumpet-shaped sound collector positioned within the housing;
a main sound bore acoustically coupled to said trumpet-shaped sound collector within the housing;
a nozzle having a nozzle opening in said body acoustically coupled to said main sound bore;
a bass sound port acoustically coupled to said nozzle opening;
an ambient sound port acoustically coupled to said nozzle opening;
a dynamic driver positioned in and acoustically coupled to said trumpet shaped sound collector; and
a balanced armature receiver positioned inside the main sound bore.

2. The in-ear monitor of claim 1 wherein said bass sound port further comprises a bass port valve that selectively restricts a sound flow through said bass sound port.

3. The in-ear monitor of claim 2 wherein said ambient sound port further comprises an ambient port valve that selectively restricts a sound flow through said ambient sound port.

4. The in-ear monitor of claim 1 wherein said nozzle includes a recessed channel and a sealing o-ring positioned on a tip of said nozzle.

5. The in-ear monitor of claim 1 further comprising a recessed cable connector.

6. The in-ear monitor of claim 1 wherein the balanced armature receiver positioned inside said main sound bore.

7. The in-ear monitor of claim 1 wherein said dynamic driver further comprises a coaxial speaker.

8. An in-ear monitor, said in-ear monitor comprising:
a housing;
a main sound bore positioned in said housing;
a dynamic driver positioned in a trumpet shaped sound collector portion of the main sound bore to acoustically couple the dynamic driver to the main sound bore; and
a balanced armature receiver positioned inside said main sound bore.

9. The in-ear monitor of claim 8 further comprising a bass port acoustically coupled to said main sound bore.

10. The in-ear monitor of claim 8 further comprising an ambient port acoustically coupled to said main sound bore.

11. The in-ear monitor of claim 8 further comprising a recessed connector for connecting said in-ear monitor to an audio source.

12. The in-ear monitor of claim 8 wherein said housing further comprises a nozzle constructed to fit in an ear canal of a user wherein said nozzle has an ear canal seal.

13. The in-ear monitor of claim 12 wherein said ear canal seal further comprises an o-ring.