# Patent

## Title
Deep insertion vented earpiece system

## Abstract

A deep insertion vented earpiece system is described including resilient earpieces shaped to a wearer's ear canal for a conformal fit. A receptacle is provided within the outer surface of each earpiece for releasably receiving an audio plug. The audio plugs include a miniature loudspeaker and a pair of external ribs for mating with a corresponding pair of grooves formed along the periphery of the receptacle. This rib and groove feature provides for a secure retention of the audio plugs while enabling a simple removal operation. Each earpiece includes an audio passage to conduct the audio signal from the loudspeaker and a vent passage to enable continuous venting of the wearer's ear to atmosphere.

## Background
CROSS REFERENCE TO RELATED APPLICATIONS
The present application is a continuation-in-part of U.S. patent application Ser. No. 11/417,281, filed on Apr. 24, 2006 now U.S. Pat. No. 7,784,583, by inventors John A. Hall, et al., entitled “Deep Insertion Vented Earpiece System,” which claims priority to Provisional Application No. 60/675,437, filed Apr. 25, 2005, entitled “Vented Earpiece System.”


RIGHTS OF THE GOVERNMENT
This invention was made in the performance of a Cooperative Research and Development Agreement with the Department of the Air Force. The Government of the United States has certain rights to use the invention.


BACKGROUND OF THE INVENTION
The present invention relates generally to personal audio/hearing protection devices and more specifically to a modular earpiece system for connection to external radios, intercom systems and the like adapted to be worn deep in the ear of the wearer, to the second bend of the ear canal.
The desirability of personal audio devices to be worn in or on the wearer's ear is well known. Indeed, the commercial market is replete with such personal audio devices enabling the wearer to enjoy listening to music or other audio presentations without disturbing those nearby. Additionally, a large market exists for personal audio devices intended for use in loud environments such as mining, manufacturing, aerospace, music or motorsports to provide clear audio communications while protecting the ear from hazardous noise.
While many of these devices fit externally, on or over the wearer's ear, and are satisfactory for their intended purpose, a need exists for personal audio devices adapted to be worn within the wearer's ear canal. Such fitted devices provide better communications clarity, better ambient noise attenuation and if fitted properly, provide greater comfort.
One earpiece system commonly used today utilizes resilient foam earpieces having loudspeakers embedded therein. The loudspeakers are operatively connected to the audio source by attached audio cables. In use, the wearer compresses the foam plug with his fingertips and inserts the foam earpiece into the ear canal. The resilient foam then expands and conforms somewhat to the wearer's ear.
While these earpiece systems are in widespread use, they are not without the need for improvement. For example, the resilient foam provides only a limited degree of conformity to the contours of the wearer's ear canal. During use, the earpieces can become uncomfortable and they also tend to fall out. Additionally, the tendency of the wearer during removal of the earpieces is to pull on the audio cables rather than on the earpieces themselves, causing the audio cables to stretch, pull out or otherwise compromise the integrity of the earpiece system. Once the audio cables are pulled out of the earpieces, the system must be discarded.
Other earpiece systems include fitted, resilient earpieces, using the wearer's own ear as a template for molding the earpiece. These fitted earpieces provide improvements in comfort and ambient noise attenuation but suffer from the above described limitations inherent in the use of attached audio cables. Moreover, these fitted earpieces do not allow the external ear to vent to atmospheric changes associated with flight operations. While this venting feature is of limited usefulness to most wearers, aircraft pilots, particularly military pilots that experience drastic altitude induced pressure changes, can suffer injury if there is no venting/equalization.
Still other earpiece systems include resilient fitted earpieces having detachable audio cables. These systems represent an improvement over the non-detachable cable systems described above by enabling a more reliable two-step removal operation wherein the wearer removes the audio cables first, before removing the earpiece. This relieves the stress placed on the components during removal. Additionally, this two-step removal operation is of particular benefit to military pilots and aircrews because the integrity of the audio system is of paramount importance.
While earpiece systems including detachable audio cables represent an improvement over the other prior art systems, a need for improvement still exists. In light of the physically demanding, fast paced environment that military pilots are exposed to, a need exists for an earpiece system having detachable audio cables that are reliably secured within the earpieces themselves. Such a system would combine the desirable detachable audio cable feature with a means for providing a secure retention of the audio cable within the earpiece during system operation. Of course, the need for venting of the ear canal, described above, and deep insertion would remain for any military flight system.
SUMMARY OF THE INVENTION
Accordingly, it is a primary object of the present invention to provide a deep insertion vented earpiece system overcoming the limitations and disadvantages of the prior art.
Another object of the present invention is to provide a deep insertion vented earpiece system including resilient earpieces conformally shaped to a wearer's ear canal.
Still another object of the present invention is to provide a deep insertion vented earpiece system including detachable audio plugs releasably retained within the earpieces.
Yet another object of the present invention is to provide a deep insertion vented earpiece system including conformally shaped resilient earpieces including a capillary vent passage to vent the external ear to atmosphere.
It is yet another object of the present invention to provide a deep insertion vented earpiece system including resilient earpieces conformally shaped to a wearer's ear canal that, when worn, terminate at the second bend of the wearer's ear canal for optimal noise attenuation.
These and other objects of the invention will become apparent as the description of the representative embodiments proceeds.
In accordance with the foregoing principles and objects of the invention, a deep insertion vented earpiece system is described. The deep insertion vented earpiece system includes a pair of deep fitting resilient earpieces custom sized and manufactured to fit the contours of the wearer's ear canals exactly (from impressions of the wearer's ears), to enhance comfort and maximize the attenuation of ambient noise. The earpieces are manufactured from silicone or other compliant, hypo-allergenic material and are cast from a custom mold made of the wearer's ear by techniques known to those having ordinary skill in the art. As used throughout, the term “deep fitting” or “deep insertion” pertains to custom fitted earpieces manufactured to be inserted such that the tip of the device rests against the second bend of the external ear canal. This deep insertion aspect of our invention represents a dramatic departure from the prior art earpieces that are made to be inserted to the first bend of the ear canal. Advantageously, this deep insertion feature of our invention has been demonstrated by extensive testing to provide superior noise reduction over the prior art earpieces.
The deep insertion vented earpiece system of the present invention additionally includes a pair of audio plugs that are removably insertable into a corresponding pair of receptacles provided within the outer surface of the earpieces. The audio plugs each include a miniature loudspeaker mounted within to provide an acoustical audio signal. Advantageously and according to an important aspect of the present invention, the audio plugs include a pair of externally mounted, parallel ribs to mate with corresponding grooves provided within the receptacles when inserted therein. This rib and groove feature of the present invention advantageously enables a secure retention of the audio plugs while enabling a simple removal operation.
The earpieces each include an audio passage to enable transmission of an audio signal between the loudspeaker within the audio plugs and the eardrum. Advantageously and according to an important aspect of the present invention, a capillary vent passage is also provided to enable continuous venting of the wearer's ear to atmosphere. This enhances user comfort while substantially avoiding middle ear barotrauma, a condition of discomfort in the ear caused by pressure due to an inability to equilibrate to ambient pressure changes.



BRIEF DESCRIPTION OF THE DRAWING
The accompanying drawing incorporated in and forming a part of the specification, illustrates several aspects of the present invention and together with the description serves to explain the principles of the invention. In the drawing:
FIG. 1 is a diagrammatic cross sectional view of the deep insertion vented earpiece system of the present invention shown installed in a user's ear;
FIG. 2 is a plan view of an audio plug of the deep insertion vented earpiece system of the present invention;
FIG. 3 is a cross sectional view of an earpiece of the deep insertion vented earpiece system of the present invention;
FIGS. 4a and 4b are perspective views of an earpiece of the deep insertion vented earpiece system of the present invention;
FIG. 5 is an illustration of an audio plug harness for use with the deep insertion vented earpiece system of the present invention; and,
FIG. 6 is an illustration of the present invention in an ear canal from a neck up (or top down) orientation to show ear canal bends.
FIG. 7 is an illustration of an earpiece system.



DETAILED DESCRIPTION OF THE INVENTION
Reference is made to FIG. 1, showing a portion of the deep insertion vented earpiece system 10 of the present invention placed within the ear of a wearer. As will be described in more detail below, the deep insertion vented earpiece system 10 includes a pair of resilient, fitted earpieces 12 adapted to be worn within the ear. The earpieces 12 are custom sized and manufactured to fit the contours of the wearer's ear canals exactly (from impressions of the wearer's ears), to enhance comfort and maximize the attenuation of ambient noise. The earpieces 12 are manufactured from silicone or other compliant, hypo-allergenic material and are cast from a custom mold made of the wearer's ear by techniques known to those having ordinary skill in the art.
As used throughout and shown in FIG. 6, the term “deep fitting” or “deep insertion” pertains to custom fitted earpieces 12 manufactured to be inserted such that a tip T of the device rests against a second bend 56 of an external ear canal 53. This deep insertion aspect of our invention represents a dramatic departure from the prior art earpieces that are made to be inserted to a first bend 55 of the ear canal 53. Advantageously, this deep insertion feature of our invention has been demonstrated by extensive testing to provide superior noise reduction over the prior art earpieces. The view of FIG. 6 is from a person's neck up (or top down) to show the ear canal bends which are less visible from a typical face view as shown in FIG. 1. It should be pointed out that while the preferred embodiment of the present invention employs a pair of earpieces, satisfactory operation may be obtained in some situations from the use of only one earpiece and thus the invention should not be considered so limited.
As shown in FIGS. 1 and 2, the deep insertion vented earpiece system 10 also includes a pair of audio plugs 14 that are removably insertable into a corresponding pair of receptacles 16, (FIGS. 3, 4a and 4b) provided within the outer surface S of the earpieces 12. The audio plugs 14 each include an internally mounted miniature loudspeaker 18, as shown in FIG. 1, to provide an acoustical audio signal from a radio, intercom system or the like. Advantageously and according to an important aspect of the present invention, the audio plugs 14 include a pair of externally mounted, parallel ribs 20, shown in FIG. 2, to mate with corresponding grooves 21 shown in FIG. 3 provided within the receptacles 16 when inserted therein. This rib and groove feature of the present invention advantageously enables a secure retention of the audio plugs 14 during use while enabling a simple removal operation, due to the resilient nature of the earpieces 12.
The separable feature of the earpieces 12 and the audio plugs 14 provides yet another advantage of the present invention in that the audio plugs 14 and the harness H, shown in FIG. 5, can be made to a standardized design. Only the earpieces 12 are custom made to the wearer. In this way, the deep insertion vented earpiece system 10 of the present invention can be readily adapted to a wide variety of users because each wearer is thus able to use his own custom molded earpieces 12 with any set of loudspeaker plugs 14 avoiding an expensive replacement of the entire assembly should the earpieces 12 or audio components fail.
As shown in FIGS. 3, 4a, and 4b, the earpieces 12 each include an audio passage 24 in fluid communication with the receptacle 16 and an inner tip T of the earpiece 12. Additionally, when the audio plug 14 is inserted into the receptacle 16, the loudspeaker 18 is correspondingly placed in fluid communication with the audio passage 24. In this way, a passage for conducting the acoustical audio signal from the loudspeaker 18 to the ear is provided. Advantageously and according to an important aspect of the present invention, a capillary vent passage 26, enabling fluid communication between the inner tip T and the outer surface S of the earpiece 12, is also provided to enable continuous venting of the wearer's ear to atmosphere. This enhances user comfort while substantially avoiding middle ear barotrauma, a condition of discomfort or injury to the ear caused by pressure resulting from an inability of the ear to equilibrate to ambient pressure changes. After extensive testing, it has been determined that a vent passage 26 diameter of 0.020′′ provides satisfactory vent performance.
As shown in FIG. 7, an earpiece system 70 includes an audio plug 74 and an earpiece 76. The audio plug 74 and the earpiece 76 have matching inverse non-cylindrical shapes. The non-cylindrical shape of the audio plug 74 and the earpiece 76 inhibits rotation of the audio plug 74 when mated with the earpiece 76. The non-cylindrical shape helps to maintain proper orientation of the audio plug 74 and increases the force necessary to accidentally detach the audio plug 74 from the earpiece 76 when subjected to downward force 78. Downward force 78 is defined as in a direction from a wearer's ear generally toward their belly button. The downward force required to dislodge the audio plug 74 from the earpiece 76 is between about 12 to 15 lbs, which is greater than the about 5 to 8 lbs of downward force required to pull the earpieces from the ear. In one example, the audio plug 74 may be removable from the earpiece 76 with a downward force at least about 1.5 times that required to remove the earpiece from the ear. This design ensures that the application of a downward force will pull the earpiece system 10 from the ear before pulling the audio plug 74 out of the earpiece 76. Conversely, an upward force 77 of approximately 3 to 5 lbs is required to remove the audio plug 74 from the earpiece 76. Upward force 77 is defined as in a direction from a wearer's ear generally slightly out from the ear and toward the top of their head. This design attribute provides for easy removal of the audio plugs 74 when the earpiece 76 is not being removed from the ear or when it is not in the ear.
As exhibited in FIG. 2, a cord angle 22 of the audio plugs 14 lies between a line parallel to the rib 20 and a cord 28. The cord angle may be between about 2 and about 8 degrees. In one embodiment the cord angle 22 may be between about 4 degrees and about 6 degrees. In one embodiment the cord angle 22 may be between about 5 degrees and about 6 degrees. In one embodiment the cord angle 22 may be about 5.24 degrees. This cord angle 22 holds the audio plug cord 28 away from the ear to minimize rubbing and discomfort to the user, as well as minimizes any torque or pressure on the housing while worn under a helmet ear cup.
The parallel ribs 20 of the audio plugs 14 have a front lead angle 23 that is sloped in this embodiment at about 60 degrees to allow ease of insertion into the custom earpiece (FIG. 6). This particular lead angle 23 of the parallel ribs 20 provides the best possibility for preventing air from escaping around the parallel ribs 20 and effectually reduces air leaks which can decrease both the efficiency of the loudspeaker 18 and the noise attenuation properties of the earpiece system 10 (FIG. 1). The front lead angle 23 creates a rib surface 27 on the parallel ribs 20. This rib surface 27 provides both a redundant seal and stiffens the ribs 20 for a more secure insertion. Additionally, parallel ribs 20 are mated to a matching receptacle 16 (FIGS. 3, 4a and 4b) in the earpiece that is sized slightly smaller than the audio plug housing to provide a robust seal. The distance between the parallel ribs 20 is designed to ensure that the silicone earpiece material will suffer less tear or wear after repeated insertions and removals from the earpiece (FIG. 6). The distance between ribs in one embodiment is less than the width of the rib surface 27.
The earpiece may be composed of hardened silicone material. The portion of the earpiece that is inserted in the ear canal may be made of clear silicone, allowing for visual verification that the tube 26 (FIGS. 3, 4a, 4b) has not become occluded by ear wax or other debris. The main body of the earpiece may be composed of silicone manufactured in any color. The clear canal piece and the body of the earpiece may be cured as a single entity. To properly contour an intertragic notch of the ear, the earpiece receptacle 16 (FIGS. 3, 4a, 4b) is non-cylindrical in shape with a tapered lower portion that matches the contour of the ear. This design takes up less space in the lower concha and intertragic notch of the ear, allowing for a more secure fit of the earpiece in the inner ear. Additionally, the alignment of the earpiece receptacle 16 (FIGS. 3, 4a, 4b) with the intertragic notch provides an optimal exit location for the audio plug 14 and the attached audio plug cable by decreasing the possibility of discomfort due to rubbing on the ear.
In summary, numerous benefits have been described from utilizing the principles of the present invention. The present invention provides a deep insertion vented earpiece system 10 shaped to a wearer's ear canal for a conformal fit. A receptacle 16 is provided within the outer surface of each earpiece 12 for releasably receiving an audio plug 14. The audio plugs 14 include a miniature loudspeaker 18 and a pair of external ribs 20 for mating with a corresponding pair of grooves 21 formed along the periphery of the receptacle 16. Each earpiece 12 includes an audio passage 24 to conduct the audio signal from the loudspeaker and a capillary vent passage 26 to enable continuous venting of the wearer's ear to atmosphere.
The foregoing description of the preferred embodiment has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiment described was chosen to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled.

## Claims

1. A deep insertion vented earpiece system for an ear with an ear canal, the ear canal having a first bend and a second bend, said deep insertion vented earpiece system comprising:
a resilient earpiece, said resilient earpiece being custom shaped to the ear canal for a conformal fit therein to maximize attenuation of ambient noise; said resilient earpiece made of silicon including an inner tip and an outer surface, wherein said inner tip rests against the second bend of the ear canal;
an asymmetrical receptacle within said outer surface of said resilient earpiece, said asymmetrical receptacle having a pair of parallel spaced compliant grooves along a periphery thereof;
an audio plug having a loudspeaker received therein, said audio plug having an outer periphery sized to conform to said periphery of said asymmetrical receptacle for releasable insertion therein, wherein said loudspeaker amplifies an audio signal received from said audio plug, said audio plug further including a pair of parallel spaced compliant ribs projecting externally from said outer periphery thereof, said ribs having a front leading angle of about 60 degrees creating a rib surface sized to conform to said grooves on said periphery of said asymmetrical receptacle to create an acoustic seal,
said audio plug further including a cord with a cord angle of between about 4 degrees and about 6 degrees, wherein said front leading angle of about 60 degrees and said cord angle of between about 4 degrees and about 6 degrees allow said audio plug to be removed from said resilient earpiece without removing said resilient earpiece from the ear canal;
an audio passage within said resilient earpiece in fluid communication with said asymmetrical receptacle and said inner tip of said resilient earpiece, said audio passage further being in fluid communication with said loudspeaker when said audio plug is inserted into said asymmetrical receptacle; and
a vent passage within said resilient earpiece, said vent passage being in fluid communication with said audio passage and said outer surface of said resilient earpiece.