Abstract:
An earplug shaping device compresses a compressible earplug prior to insertion of the earplug into a user&#39;s ear canal. The device includes a first member and a second member which rotate with respect to each other. The outer surface of the first member and inner surface of the second member define a space that decreases in size as the first and second members rotate with respect to each other, thereby compressing the compressible earplug. Various embodiments of the earplug shaper employ a ratchet mechanism permitting substantially only one direction of rotation.

Description:
FIELD 
     This invention relates generally to earplug shaping devices. More particularly, the present invention relates to a portable device uniquely configured to uniformly shape PVC, polyethylene and other resilient/slow recovery earplugs to a proper pre-insertion diameter to enhance effective use of the earplugs. 
     BACKGROUND 
     In manufacturing, construction and other noisy environments, continued exposure to high sound levels can cause hearing loss. Repeated exposure to noise levels above 90 decibels can cause hearing loss in a relatively short time. Hearing loss has become such a problem in the United States that OSHA requires any workers who are continually exposed to an ambient noise level above 90 decibels to wear hearing protection. 
     Hearing loss arising out of continued exposure to high sound levels can easily be avoided or greatly reduced by the use of hearing protection devices, such as earmuffs or earplugs. Earmuffs typically have a cup or shell which fits over the top of the ear with padding in between the shell and the user&#39;s head which helps seal out noise. While earmuffs generally work well, they are typically awkward to wear, uncomfortable and can interfere with the wearer&#39;s activities. 
     Resilient earplugs (also known as “slow recovery” earplugs) provide an alternative means of hearing protection against the noise an individual is subjected to. Resilient earplugs can be fabricated from a variety of materials including silicon, various plastics, PVC and polyethylene. Two of the more common materials used are PVC and polyethylene. These materials provide an earplug which can be compressed to a small diameter and inserted into the ear canal. Once in the ear canal, the earplug slowly expands or recovers to seal against the interior surface of the ear canal, thereby inhibiting noise or sound from entering the ear canal. 
     Pre-insertion shaping of the earplug is typically accomplished by rolling the earplug between the thumb and index finger. Unfortunately, users frequently fail to roll and compress the earplugs to the proper pre-insertion diameter. When this happens, the earplug will not function to its full potential. 
     Another problem associated with resilient earplugs occurs when creases are introduced into the outer surface of the earplug as it is being rolled and compressed. Creases introduced during pre-insertion shaping of the earplug can provide a pathway for sound to enter the ear canal, which further reduces the effectiveness of the earplug. 
     Yet another problem associated with resilient earplugs is that dirt and grime is often transferred from the user&#39;s hands to the earplug as it is being handled and shaped prior to insertion. In addition to being unsightly, soiled earplugs have the potential to introduce infectious pathogens into the ear canal. And because of their unsightly appearance, soiled earplugs are often discarded after only one use, which is wasteful. 
     While there currently exist devices capable of rolling earplugs, these devices are not portable. Additionally, prior earplug rolling devices are not capable of being easily disassembled for cleaning and also do not provide the capability of storing earplugs within the device. 
     For the foregoing reasons, there is a need for an earplug shaping device that is portable and enhances the use and effectiveness of resilient earplugs. 
     SUMMARY 
     The present invention is directed to a portable device for pre-insertion shaping of a resilient earplug to a proper diameter without introducing creases in the surface of the plug. The device includes first and second members that compress an earplug when the two members are rotated with respect to each other. Either the first or the second member may have a radius that varies from minimum value to a maximum value, while the other member has a substantially constant radius. Various embodiments of the present invention also include a cap configured to enclose the space between the two members, in addition to a hollow container for storing unused earplugs. 
     Some embodiments are directed to an apparatus having a first member, a second member, and a space there between. The first member, which is configured to rotate about a rotational axis, has an outer surface for contacting the earplug. The outer surface of the first member is disposed about the rotational axis at a distance R 1  from the rotational axis. The distance R 1  varies from a minimum value at a first location on the outer surface to a maximum value at a second location on the outer surface. The second member has an inner surface for contacting the earplug. The inner surface is disposed about the rotational axis at a substantially constant distance R 2  from the rotational axis, where R 2  is greater than R 1 . Between the outer surface of the first member and the inner surface of the second member is the space for accommodating the earplug. When the device is operated, the earplug is compressed between the outer surface of the first member and the inner surface of the second member as the first member rotates about the rotational axis in relation to the second member. Alternatively, the second member may rotate about the rotational axis in relation to the first member. 
     In some embodiments, the outer surface of the first member is disposed about the rotational axis at a substantially constant distance R 1  from the rotational axis, and the inner surface of the second member is disposed about the rotational axis at a distance R 2  which is greater than the distance R 1 , and the distance R 2  varies from a minimum value at a first location on the inner surface to a maximum value at a second location on the inner surface. 
     In some embodiments, the outer surface of the first member is disposed about the rotational axis at a distance R 1  which varies from a minimum value at a first location on the outer surface to a maximum value at a second location on the outer surface. In these embodiments, the inner surface of the second member is disposed about the rotational axis at a distance R 2  which is greater than the distance R 1 , and the distance R 2  varies from a minimum value at a first location on the inner surface to a maximum value at a second location on the inner surface. 
     One of the advantages of a curved roller structure over a linear structure is that the distance necessary to get a full compression of an earplug can be accommodated within a fairly compact and portable package. An equivalent length linear path would be too long to practically implement because the product would be too large to be carried with the user. Also, the longer rolling surface of the embodiments described herein allows a wider variety of models of earplugs to be rolled using one rolling device. 
     Another advantage of some embodiments described herein is the provision of a storage compartment for storing earplugs within the structure. 
     Yet another advantage is that the design allows for the device to be taken apart and cleaned. Maintaining the cleanliness of the earplugs reduces the amount of dirt and/or bacteria in the ear. 
     Yet another advantage is in the process of turning the device to move the first member relative to the second member. The turning process generally slows down the process of rolling which makes for a more consistent compression, whereas prior shaping devices having linear shaping surfaces required one linear move which could occur too rapidly, causing improper compression. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Preferred embodiments of the invention will now be described in further detail. Other features, aspects, and advantages of the present invention will become better understood with regard to the following detailed description, appended claims, and accompanying drawings (which are not to scale) where: 
         FIG. 1  shows an exploded view of an embodiment of an earplug shaper; 
         FIG. 2  shows a top view of a first member of the embodiment of  FIG. 1 ; 
         FIG. 3  shows a view of a ratchet arm of the first member depicted in  FIG. 2 ; 
         FIG. 4  shows a top view of a second member, a container, and a bottom member of the embodiment of  FIG. 1 ; 
         FIG. 5  shows a cross-sectional side view of the second member, container, and bottom member of the embodiment of  FIG. 1 ; 
         FIG. 6  shows a top view of a cap member of the embodiment of  FIG. 1 ; 
         FIG. 7  shows a bottom view of the cap member; and 
         FIG. 8  shows a cross-sectional view of the first member disposed in relation to the second member. 
     
    
    
     DETAILED DESCRIPTION 
     Preferred embodiments of the present invention will now be described with reference to the accompanying drawings, wherein like reference characters designate like or similar parts throughout. The terminology used herein is intended to be interpreted in its broadest reasonable manner, even though it is being utilized in conjunction with a detailed description of certain specific preferred embodiments of the present invention. This is further emphasized below with respect to some particular terms used herein. Any terminology intended to be interpreted by the reader in any restricted manner will be overtly and specifically defined as such in this specification. 
     With respect to the embodiment of  FIG. 1 , a resilient earplug shaper  20  includes a first member  12 , a second member  14  and a cap member  16 . The first member  12 , second member  14  and cap member  16  may be fabricated from a variety of materials including wood, metal, plastic and composite materials. In a preferred embodiment, the first member  12 , second member  14  and cap member  16  are molded from polycarbonate. 
     The first member  12  includes an outer surface  18  configured to rotate about a rotational axis with respect to the second member  14 . In a preferred embodiment illustrated in  FIG. 2 , the radius R 1  of the outer surface of the first member  12  is variable, and varies from a minimum value R 1 ′ at a first point P 1  to a maximum value R 1 ″ at a second point P 2 . Most preferably the radius R 1  of the outer surface  18  of the first member varies constantly between the first point P 1  and the second point P 2  such that the radius R 1  of the outer surface  18  of the first member  12  substantially defines a spiral. In an alternative embodiment, the radius R 1  of the outer surface  18  of the first member  12  is constant, such that the radius R 1  of the outer surface  18  of the first member  18  substantially defines a circle. 
     In the embodiment illustrated in  FIG. 2  the first member  12  includes one or more ratchet arms  22 . The ratchet arms  22  are preferably connected to an upper lip portion  28  of the first member  12  and are disposed within the radius defined by the outer surface  18 . As shown in  FIG. 2 , the ratchet arms  22  preferably extend inward with respect to the outer surface  18  of the first member  12 . With respect to  FIG. 3 , each ratchet arm  22  includes one or more teeth  32  that are uniformly disposed toward an end of the ratchet arm  22 . The teeth  32  of the ratchet arm  22  are generally facing toward the rotational axis of the first member  12 . 
     With further reference to  FIG. 2 , the first member  12  also preferably includes a cavity  24  at least partially defined by an indentation in the outer surface  18 . The cavity  24  is substantially disposed near the second point P 2  of the outer surface  18 . 
     The first member  12  also preferably includes one or more apertures  26  positioned around the circumference of the upper lip portion  28  of the first member  12 . 
       FIG. 4  illustrates a preferred embodiment of the second member  14 . The second member  14  includes an inner surface  42  that is configured to rotate about the rotational axis with respect to the first member  12 . In a preferred embodiment, the radius R 2  of the inner surface  42  of the second member  14  is substantially constant so as to define a circle. However, in alternative embodiments, the radius R 2  of the inner surface of the second member  14  may vary from a minimum value at a first location to a maximum value at a second location, and in some embodiments the radius R 2  of the inner surface  42  of the second member  14  substantially defines a spiral. Additionally, the second member  14  includes a bottom surface  46  that substantially encloses a lower portion of the second member  14 . 
     As shown in  FIG. 5 , the second member  14  may also include a hollow cylindrical storage cavity  52  disposed centrally about the rotational axis. The hollow storage cavity  52  has a radius R 3  that is less than the radius R 1  of the first member  12 . 
     As shown in  FIG. 4 , the second member  14  preferably includes a plurality of notches  44  disposed radially about the rotational axis. The notches  44  are preferably formed in an external surface  53  of the hollow storage cavity  52 , with the radius of the notches  44  being substantially equivalent to the radius R 3  of the hollow storage cavity  52 . 
       FIG. 6  illustrates a cap member  16  according to a preferred embodiment. The cap member  16  preferably defines a circle having a radius R 4  that is greater than the radius R 2  of the inner surface  42  of the second member  14 . The cap member  16  preferably includes a keyhole  62  located at the center of the cap member  16 . The cap member  16  preferably includes both a first passageway  64  and a second passageway  66 . The first passageway  64  is sized such that a fully uncompressed earplug may pass through the first passageway  64 . The second passageway  66  is preferably sized such that a fully compressed earplug may pass through the second passageway  66 . 
     With reference to  FIG. 7 , the cap member  16  further includes one or more pins  72 . The outside diameter of the pins  72  is preferably sized such that the pins  72  may be press fit into the apertures  26  of the first member  12 , thereby substantially connecting and securing the cap member  16  to the first member  12 . 
     With reference to  FIG. 8 , the first member  12  is preferably placed within the second member  14  such that the axes of rotation of the two members are substantially collinear. In this position, there is a space  15  defined between the outer surface  18  of the first member  12  and the inner surface  42  of the second member. 
     The cap member  16  is placed over the second member  14  and engages the first member  12  as the pins  72  of the cap member  16  press into the apertures  26  of the first member  12 . A key member  19  is preferably positioned within the hollow storage cavity  52  and engages the keyhole  62 , thereby securing the cap member  16  to the second member  14  and capturing the first member  12  between the cap member  16  and the second member  14 . A removable cover member  17  may be attached to the outer portion of the second member  14  causing the hollow storage cavity  52  to be substantially enclosed. 
     In a preferred embodiment, the outer surface  18  of the first member  12  and the inner surface  42  of the second member  14  are textured, such as with dimpling or ridges or other texturing that introduces friction between the surface  18  and the earplug and between the surface  42  and the earplug. It is desirable for the earplug to roll between the surfaces  18  and  42  as it is compressed between them. The texturing on the surfaces  18  and  42  prevents the earplug from slipping with respect to the surfaces and promotes rolling. 
     To use the earplug shaper  20 , a resilient earplug is inserted into the resilient earplug shaper  20  through the first passageway  64  such that it is capture between the outer surface  18  of the first member  12  and the inner surface  42  of the second member  14  at the first point P 1 . The combination of the cap member  16  and the first member  12  is rotated with respect to the second member  14 . In a preferred embodiment, as the cap member  16  and first member  12  rotate with respect to the second member  14 , the distance between the outer surface  18  of the first member  12  and the inner surface  42  of the second member  14  decreases at the location where the earplug is captured between the two surfaces. This causes the earplug to be rolled and compressed between the outer surface  18  of the first member  12  and the inner surface  42  of the second member  14  until the earplug reaches the second point P 2  of the first member  12 . The fully compressed earplug then passes into the cavity  24 , which is preferably in alignment with the second passageway  66 . The resilient earplug shaper  20  is then preferably turned upside down to eject the fully compressed earplug for insertion into the user&#39;s ear. 
     With reference to the embodiment depicted in  FIGS. 2 ,  3  and  4 , the ratchet arm  22  of the first member  12  engages the notches  44  of the second member  14 . When the cap member  16  and the first member  12  rotate together in relation to the second member  14 , the teeth  32  of the ratchet arm  22  engage the notches  44  of the second member  14 . The notches  44  of the second member  14  are preferably directional in shape, such that as the teeth  32  of the ratchet arm  22  engage the notches  44  of the second member  14 , only one direction of rotation is permitted. 
     In preferred embodiments, the outer surface  18  of the first member  12  has a radius R 1  that varies from a first point P 1  to a second point P 2 , so as to define a spiral, and the inner surface  42  of the second member  14  defines a circle. However, in other embodiments the inner surface  42  of the second member  14  has a radius R 2  that varies from a minimum value at one point to a maximum value at another point, and the outer surface  18  of the first member  12  substantially defines a circle. In yet other embodiments, the inner surface  42  of the second member  14  and the outer surface  18  of the first member  12  both have a radius that varies from a maximum value to a minimum value. Accordingly, embodiments of the invention include any other like configuration wherein the first member  12  rotates in relation to the second member  14 , thereby causing the space  15  at any particular point between the outer surface  18  of the first member  12  and the inner surface  42  of the second member  14  to decrease as the two members are rotated in relation to each other. 
     In an alternative embodiment of the present invention, an electrical motor is preferably mounted within the resilient earplug shaper  20 , such as within the hollow storage cavity  52 . The electrical motor is preferably connected to the first member  12  such that when the user depresses a switch, the first member is rotated with respect to the second member  14 , thereby compressing the resilient earplug. 
     In yet another alternative embodiment, a resilient earplug dispenser incorporates a resilient earplug shaper for automatically dispensing multiple compressed earplugs. When a user desires a pair of resilient earplugs, a switch is depressed causing a pair of resilient earplugs to enter a resilient earplug shaper. The resilient earplugs are then compressed within the resilient earplug shaper by rolling the earplugs between an outer and inner surface according to the embodiments of this invention, and the compressed resilient earplugs are then ejected from the apparatus for insertion into the ear of the user. 
     The foregoing description details certain preferred embodiments of the present invention and describes the best mode contemplated. It will be appreciated, however, that changes may be made in the details of the construction and the configuration of components without departing from the spirit and scope of the disclosure. Therefore, the description provided herein is to be considered exemplary, rather than limiting, and the true scope of the invention is that defined by the following claims and the full range of equivalency to which each element thereof is entitled.