Patent Publication Number: US-8111864-B2

Title: Earbud adapter

Description:
RELATED APPLICATIONS 
     This application is a continuation of U.S. application Ser. No. 10/753,591, filed Jan. 7, 2004, the entire disclosure of which is incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention pertains to sound devices and adapters or devices for use with sound devices. More particularly, the present invention pertains to adapters for use with earbud-type headphones that improve the comfort of the headphones, isolate the ear from extraneous sounds, and provide a number of other desirable features. 
     BACKGROUND OF THE INVENTION 
     Sound devices such as headphones are used extensively throughout the world. One style of headphones that is commonly used is referred to as an earbud or an earbud-type headphone. Earbuds are small speaker-like devices that are designed to fit within the external ear of a listener so that the user can listen to sound being transmitted from a sound source. Some examples of typical sound sources where earbuds may be used include personal and/or portable audio players (including radios, cassette players, compact disc players, portable mp3 players, etc.), portable DVD players, telephones (including wireless and cellular-type telephones), etc. When properly positioned in the ear, earbuds can provide the listener with acceptable sound transmission to the ear canal. However, due to person-to-person variations and variations in the environment in which the earbuds are used, fit may not be adequate and extraneous noise may make transmission inadequate. 
     A wide variety of headphones and earbuds have been developed as well as a number of adapters and prostheses attachable to these devices. In addition, a wide variety of methods for manufacturing headphones (including ear buds) and adapters have been developed. Among these known devices and methods, each has certain advantages and disadvantages. There is an ongoing need to provide alternative devices and methods for making these devices which improve sound transmission, isolate extraneous noise and provide improved comfort and fit. 
     BRIEF SUMMARY 
     The present invention relates to sound devices and adapters and/or prostheses for use with sound devices. In at least some embodiments, an example adapter may include an adapter body having a first side, a port or projection extending from the first side, and a second side. The second side is generally configured to be releasably attachable to an earbud or earbud-type headphone which would be positioned in the outer ear during use. The projection may include a sleeve attached thereto. The projection in one embodiment or the projection and sleeve in an alternative embodiment are generally configured to extend into the ear canal of a user. In preferred embodiments, a sleeve or foam cover is positioned over the sleeve to provide a contact surface which generally conforms to the users ear canal shape when at least a portion of the sleeve is positioned therein. Some of these and other features are described in more detail below. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an example adapter; 
         FIG. 2  is an alternative perspective view of the example adapter depicted in  FIG. 1 ; 
         FIG. 3  is a side view of an example sleeve for use with an adapter; 
         FIG. 4  is a cross-sectional view of the sleeve depicted in  FIG. 3 ; 
         FIG. 5  is an exploded view of an example sound device, adapter, and sleeve; 
         FIG. 6  is a perspective view showing the connection of the sound device, adapter, and sleeve; 
         FIG. 7  is a cross-sectional view of an example coupling member; 
         FIG. 8  is a cross-sectional view of the coupling member of  FIG. 7  attached to a sleeve; 
         FIG. 9  is a cross-sectional view of another example coupling member; 
         FIG. 10  is a cross-sectional view of the coupling member of  FIG. 9  attached to a sleeve; 
         FIG. 11  is an exploded view of another example adapter body, coupling member, and sleeve; 
         FIG. 12  is an exploded view of still another example adapter body, coupling member, and sleeve; 
         FIG. 13  is an exploded view of still another example adapter body, coupling member, and sleeve; and 
         FIG. 14  is a perspective view of another example sleeve. 
     
    
    
     DETAILED DESCRIPTION 
     The following description should be read with reference to the drawings wherein like reference numerals indicate like elements throughout the several views. The detailed description and drawings illustrate example embodiments of the claimed invention. 
       FIGS. 1 and 2  are perspective views of an example adapter body  10  for use with an earbud or an earbud-type sound device or headphone. Adapter  10  includes a top side or portion  12 , as best seen in  FIG. 1 , and a bottom side or portion  14 , as best seen in  FIG. 2 . A projection or port  16  extends from top side  12 . A port opening  18  is defined in projection  16 . In some embodiments, opening  18  is at the distal terminus of projection  16 . In other embodiments, opening  18  can be disposed at other locations along projection  16 . A second opening  20  is defined in adapter body  10  that is disposed on bottom side  14 . A sound conduit  22  is defined in adapter body  10  that extends between opening  18  and opening  20 . Sound conduit  22  generally allows sound to pass from a sound device (to which adapter body  10  is attached), into and through opening  20 , through projection  16 , through and out from opening  18 , and into the ear canal of a user. 
     Adapter body  10  is configured to be attachable to an earbud or earbud-type sound device. An earbud or earbud-type device is one that normally rests within the outer ear during use without extending into the ear canal. Preferably, adapter body  10  is configured for being detachably connectable to a sound device. This feature allows a user to freely attach and detach adapter body  10  as desired. However, the adapter body  10  is held in place with sufficient force to retain its position on the sound device during use. In addition, the user may discard adapter body  10  after use, if desired, and replace it with a new one for subsequent uses. The earbud or earbud-type sound device may be a part of a cell phone headset, CD player or any other sound transmission device. It may include one or more ear buds. 
     The materials used to manufacture adapter body  10  may vary. In some embodiments, adapter body  10  is made from a polymer. Because a number of polymers are relatively inexpensive, constructing adapter body  10  from a polymer may desirably impact the manufacturing costs. In addition, because of the relatively low manufacturing costs that are contemplated, adapter body  10  may be inexpensive for the consumer and disposable. Some examples of suitable polymers may include ethylene tetrafluoroethylene (ETFE), fluorinated ethylene propylene (FEP), polyoxymethylene (POM), polybutylene terephthalate (PBT), polyether block ester, polyurethane, polypropylene (PP), polyvinylchloride (PVC), polyether-ester (for example, a polyether-ester elastomer such as ARNITEL® available from DSM Engineering Plastics), polyester (for example a polyester elastomer such as HYTREL® available from DuPont), polyamide (for example, DURETHAN® available from Bayer or CRISTAMID® available from Elf Atochem), elastomeric polyamides, block polyamide/ethers, polyether block amide (PEBA, for example, available under the trade name PEBAX®), silicones, polyethylene (PE), Marlex high-density polyethylene, Marlex low-density polyethylene, linear low density polyethylene (for example, REXELL®), polyethylene terephthalate (PET), polyetheretherketone (PEEK), polyimide (PI), polyetherimide (PEI), polyphenylene sulfide (PPS), polyphenylene oxide (PPO), polysulfone, nylon, perfluoro(propyl vinyl ether) (PFA), other suitable materials, or mixtures, combinations, copolymers thereof, polymer/metal composites, and the like. 
     As suggested above, bottom portion  14  is configured so that adapter body  10  can releasably attach to a sound device. In some embodiments, bottom  14  can include a ridge or rim  24  that is adapted to fit over and generally be disposed along the perimeter of the earbud or earbud-type sound transmitting device. It can be seen in  FIG. 2  that rim  24  may be generally circular in shape so as to correspond to the generally circular and/or conical shape of the sound device. However, other shapes are contemplated, depending on the shape of the sound device. For example, rim  24  could be oval, squared, polygonal, etc. so as to improve the compatibility, attachability, and detachability of adapter body  10  to a variety of sound devices. In addition, one or more notches  26  may be defined in rim  24 , which can allow rim  24  to adjust to somewhat differently sized or shaped sound devices and allow adapter body  10  to more easily attach and detach from the sound device while providing sufficient frictional engagement. This feature may allow a consumer to use one particular adapter body  10  embodiment with a number of differently sized or shaped sound devices. 
     Projection or port  16  is generally configured for extending into the ear canal of a user during use. In order for projection  16  to be properly positioned and/or seated in the ear canal, projection  16  preferably extends at a selected angle θ from the plane defined by top portion  12 , as shown in phantom in  FIG. 1 . By being disposed at a selected angle, the design of adapter body  10  allows top portion  12  to rest in the outer ear while still allowing projection  16  to extend into the external auditory meatus (i.e., the auditory or ear canal). In one preferred embodiment, the angle θ is between about 0 degrees to about 45 degrees. In another preferred embodiment, projection  16  is disposed at an angle of about 15±10 degrees. These ranges assume that adapter body  10  is positioned in the ear in a manner so that the contours of top portion  12  are substantially parallel to the contours of the concha (i.e., the bowl of the ear). It can be appreciated that angle θ can vary outside these ranges, particularly if adapter body  10  is positioned in the ear in a manner so that top portion  12  is not substantially parallel to the concha. For example, if the adapter body  10  is disposed at another position in the ear, partially or completely behind the ear, or at some other location, a number of differing angles θ are contemplated. In addition, the material composition and design of adapter body  10  may allow angle θ to be variable for any particular adapter body  10 . For example, adapter body  10  may be configured so that angle θ can bend or flex so that adapter body  10  can fit more comfortably in a variety of different users&#39; ears. According to this embodiment, angle θ may vary within any given adapter body  10 . 
     In preferred embodiments, a sleeve or foam cover  28  may be coupled to projection  16 . Sleeve  28  may be coupled to projection  16  in any number of suitable manners such as with an adhesive. Alternatively, sleeve  28  may be attached using a coupling member as described in more detail below. A side view of an example sleeve  28  is depicted in  FIG. 3 , and a cross-sectional view of sleeve  28  is shown in  FIG. 4 . In these Figures, it can be seen that sleeve  28  may be generally cylindrical in shape. Additionally, sleeve  28  may include a first surface  30  and an axial hole  32  in first surface  30  that extends into sleeve  28 . In some embodiments, opening  32  extends into only a portion of sleeve  28 . In other embodiments, opening  32  extends all the way through sleeve  28 . Some of the features and characteristics of a suitable sleeve  28  can be found in U.S. Pat. No. 5,920,636, the disclosure of which is incorporated herein by reference. 
     Sleeve  28  may also include a number of other structural components. For example, a lock ring  34  may be disposed at one end of sleeve  28  and attached to sleeve  28  by any suitable means. The mechanism for attaching lock ring  34  to sleeve  28  may vary. For example, lock ring  34  may be mechanically attached, adhesively bonded, thermally bonded, and the like, or otherwise attached in any suitable manner. Lock ring  34  may include a hole  36  that may be axially aligned with hole  32 . In some embodiments, lock ring  34  partially covers hole  36  so that hole  36  of lock ring  34  is smaller than axial hole  32  of sleeve  28 . In other embodiments, hole  36  is about the same size or slightly larger than axial hole  32 . Lock ring  34  may be made from a stiffer, yet deformable material such as a stiffer foam, polyethylene, polyurethane, polyethylene terephthalate, or any other suitable material including those disclosed herein. The use of lock ring  34 , and variants thereof, is described in more detail below. Sleeve  28  may also include a thin layer  38  of a sound-transmitting material or scrim (e.g., preferably a reticulated open cell foam) that helps prevent detritus or cerumen from the ear canal from entering a sound delivery tube of a sound device on which sleeve  28  may be mounted. 
     Sleeve  28  can be of many different types of materials such as a polymer or foam. Some example polymers are listed above. A number of different types of foams exist, which may be suitable for some embodiments. For example, sleeve  28  could be made of a sound attenuating slow recovery foam. This type of foam may allow the user to compress sleeve  28  with his/her fingers before it is placed in the ear canal, after which it recovers its shape sufficiently so that its periphery conforms to the inner surface of the ear canal. This feature can improve the fit and comfort of adapter body  10  (and sleeve  28 ) in the ear canal. In addition, this type of foam can substantially block sounds from entering the ear canal other than sounds transmitted from the sound device that pass through adapter body  10 . This feature may be desirable because blocking extraneous sound “isolates” the ear in which sleeve  28  is disposed from these other sounds. 
     It is believed that isolating an ear from other sounds (i.e., sounds not originating from the sound device) allows the user to better process sound coming from the sound device, even when the device is only in one ear with the other ear receiving the extraneous sounds. This allows the user to better distinguish the sounds from the sound device from other sounds that could be distracting. This feature may be particularly useful when the sound device is an earbud connected to a telephone because the user would be able to adequately hear and distinguish voices from the telephone from other sounds or voices that might be present in the area. This feature also reduces the likelihood that sounds originating from the sound device would be confused with extraneous sounds, even when the user&#39;s other ear does not have any sound device disposed therein. Moreover, by reducing the amount of unwanted sound that enters the ear, a lesser degree of energy can be delivered to the eardrum for the same level of sound perception and intelligibility. This can protect the eardrum from damage that could be caused by exposure to greater amounts of energy or otherwise help preserve or enhance the long-term health of the ear. 
     Where it is desirable to have sounds enter the ear both through the sound device and sleeve  28 , sleeve  28  can be of a more sound transmissive foam such as open cell foam or a reticulated open cell foam selected for the amount of sound transmission desired. Typically, such open cell foams are sufficiently compressible so that the periphery will conform to the inner surface of the ear canal as sleeve  28  is pushed into it. It can be appreciated that the use of a number of other types of foams and similar materials are contemplated. In addition, a plethora of other suitable materials are contemplated, including silicone rubber. 
     The following examples of dimensions for sleeve  28  are provided for illustrative purposes and are not intended to be limiting. In some embodiments, sleeve  28  can have a diameter of about 0.35 to about 0.65 inches and an axial length between its surfaces of about 0.15 to about 0.65 inches. Hole  32  may have a diameter of about 0.08 to about 0.19 inches. Lock ring  34  can be of a polymeric material about 0.005 to about 0.025 inches in thickness. Lock ring  34  can have an outer diameter of about 0.15 to about 0.30 inches. Hole  36  in lock ring  34  may have a diameter of about 0.05 to about 0.15 inches. The diameter of hole  36  can provide for a clearance fit of about 0.005±0.003 inches to an interference fit of about 0.020±0.010 inches between the lock ring  34  and the bottom of a grooved coupling (e.g., a groove defined in projection  16  or in a coupling member such as the one described below), that fit being selected to provide the degree of engagement desired between sleeve  28  and adapter body  10 . Such interference fits will cause a portion of lock ring  34  to remain in a slightly frusta-conical shape after engagement around projection  16 , which insures firm engagement therebetween. 
     An exploded view of an earbud-type sound device  40  (depicted as an earbud), adapter body  10 , and sleeve  28  is depicted in  FIG. 5 . Here the relationships of the relevant devices can be more clearly seen. For example, rim  24  of adapter body  10  can be disposed over earbud  40  so that speaker face  42  is seated adjacent bottom portion  14 . Sleeve  28  can be disposed over a portion of projection  16 . Sound emitted from earbud  40  can pass through sound hole  22  and, ultimately, into the ear canal of a user. A perspective view of earbud  40 , adapter body  10 , and sleeve  28  as connected is shown in  FIG. 6 . The adapter body  10  is rotated to a position which provides the best fit for the particular user when the port  16  extends into the ear canal and the earbud rests in the outer ear. This preferred orientation is generally depicted in  FIG. 6 . 
     As described above, sleeve  28  may be coupled to projection  16  with an adhesive or any other suitable means. Alternatively, sleeve  28  may be attached to projection  16  with a coupling member  44 . A cross-sectional view of an example coupling member  44  is shown in  FIG. 7 . Coupling member  44  may include a first end region  46 , a second end region  48 , and a sound channel  50  extending therethrough in communication with sound conduit  22  when positioned on or integrally formed with projection  16 . First end region  46  may be configured for being attached to projection  16 . For example, a groove or notch  52  may be defined adjacent first end region  46  that is adapted to engage a corresponding protrusion  54  defined in projection  16  as seen in  FIG. 8 . Groove  52  and protrusion  54  can interlock when first end  46  is disposed into projection  16 . Alternatively, first end region  46  may simply be disposed into projection  16  (regardless of whether or not projection  16  includes protrusion  54 ) and secured with an adhesive, another type of mechanical bond, a friction fit bond, a thermal bond, and the like, or any other suitable way. When coupled, the distal end  56  of projection  16  may be seated against or adjacent a shelf region  58  of coupling member  54 . 
     Second end region  48  is configured to releasably attach to sleeve  28 . For example, second end region  48  may include a sloped portion  60  and a notch  62  that is configured to engage lock ring  34 . According to this embodiment, second end region  48  can be advanced through hole  32  of sleeve  28  so that sloped portion  60  comes into contact with lock ring  34 . Further advancing second end region  48  results in sloped portion  60  passing through hole  36  in lock ring  34  so that, ultimately, lock ring  34  “snaps” into position and becomes disposed in notch  62 . This can result in a stable interference type mechanical bond between sleeve  28  and coupling member  44 . 
       FIG. 9  is a cross-sectional view of another example coupling member  144  that is shorter but otherwise similar to coupling member  44 . First end region  46  of coupling  144  may be configured for being attached to projection  16 , for example, via engagement of notch  52  with protrusion  54  or by disposing first end region  46  into projection  16  as described above. Because coupling member  144  is shorter than coupling member  44 , first end region  46  terminates or is otherwise disposed within sleeve  28  (i.e., within hole  32  of sleeve  28 ) when it is engaged with lock ring  34 . Accordingly, distal end  56  of projection  16  is also disposed within sleeve  28  when projection  16  is engaged with coupling member  144  and sleeve  28  as shown in  FIG. 10 . The relationships between the other components of coupling member  144  with sleeve  28  may be substantially similar to the relationships described above in regard to coupling member  44 . 
     In some embodiments, coupling member  44  may be “pre-attached” to or “formed integral” with adapter body  10 . This feature allows a user to simply attach sleeve  28  to projection  16  as needed and use adapter body  10  and sleeve  28  with the earbud or other sound device. Alternatively, a kit may be provided that includes adapter body  10 , coupling member  44 , and sleeve  28 . According to this embodiment, the user may attach coupling member  44  to projection  16  (e.g., as described above) and attach coupling member  44  to sleeve  28 . Either way, adapter body  10  (which may have sleeve  28  attached thereto) can be disposed over the ear bud, and sleeve  28  can be disposed in the ear canal. Alternatively, adapter body  10  can be provided with sleeve  28  permanently attached thereto. As previously stated, this entire assembly would then be disposable by the user. 
       FIG. 11  is an exploded view of another adapter body  210  for use with coupling member  244  (which may be similar to any of the coupling members disclosed herein) and sleeve  28 . Adapter body  210  is similar to adapter body  10  except that it includes a connector  264  along bottom surface  214  instead of a rim (e.g., rim  24  as best seen in  FIG. 2 ). Connector  264  can vary. In some embodiments, connector  264  includes an adhesive disk or ring  266  having a peel-away covering  268  disposed over it. Adhesive disk  266  may include a pressure-sensitive or other type of adhesive layer that is attached to bottom surface  214 . Adhesive disk  266  may or may not include a foam base or linker that is used to connect adhesive disk  266  to bottom surface  214 . To use connector  264 , a user may simply peel away covering  268  in order to expose adhesive disk  266  and then attach adapter body  210  to a sound device by pressing the two objects together with his or her fingers. In alternative embodiments, connector  264  may simply include a foam base having an adhesive surface or another suitable type of attachment means for attaching adapter body  210  to a sound device. 
     The remaining structures shown in  FIG. 11  may be substantially similar to the analogous structures depicted in the other figures. For example, adapter body  210  may include projection  216  that is similarly configured to any of the projections described herein. Coupling member  244  may be attached to projection  216  and may be adapted to attach adapter body  210  to sleeve  28 . As described above, coupling member  244  may be a distinct structural component that is attachable to sleeve  28  and projection  216 , or it may be integral with projection  216  and/or sleeve  28 . 
       FIG. 12  depicts another example adapter body  310 , coupling member  344 , and sleeve  328 . Adapter body  310  is substantially similar to adapter body  210  and may include projection  316  and connector  364 . Coupling member  344  is similar to other coupling members described herein except that second end region  348  includes a thread. As described above, coupling member  344  may be a distinct structural component that is attachable to sleeve  328  or it may be integral with projection  316  and/or sleeve  328 . 
     Threaded second end region  348  of coupling member  344  is configured to threadably engage sleeve  328 . In some embodiments, sleeve  328  includes a threaded nut portion  349  (shown in phantom) disposed in or adjacent the hole  332  of sleeve  328 . Accordingly, threaded second end region  348  can mate with threaded nut portion  349  so as to secure coupling member  344  (and, thus, adapter body  310 ) with sleeve  328 . When coupled, sleeve  328  may abut a flange portion  353  of projection  316 . Flange portion  353  provides a stopping point that will stop sleeve  328  from being screwed onto adapter body  310  any further than desired. Within sleeve  328  and extending from threaded nut portion  349  may be a flexible tapered portion  351 . Flexible portion  351  allows sleeve  328  to be flexible so that it can conform to the shape of a user&#39;s ear canal while connected to adapter body  310 . Moreover, this flexibility allows sleeve  328  to fit comfortably yet securely in the user&#39;s ear. Further suitable sleeves and coupling members that are similar in structure and function to sleeve  328  and coupling member 344 can be found in U.S. Pat. No. 5,002,151, the disclosure of which is incorporated herein by reference. 
       FIG. 13  depicts another example adapter body  410 , coupling member  444 , and sleeve  428 . Adapter body  410  is substantially similar to adapter body  310  and may include projection  416  and connector  464 . Coupling member  444  may comprise a sloped ridge configured for an interference fit with sleeve  428 , for example, at a connector region  472  disposed on sleeve  428 . According to this embodiment, a user may attach sleeve  428  to adapter body  410  by simply pushing sleeve  428  into contact with coupling member  444  in a manner that engages these structures and holds them together due to the interference-type connection. Aside from connector region  472 , sleeve  428  may be similar to any of the other sleeves described herein. As described above, coupling member  444  may be a distinct structural component that is attachable to sleeve  428  or it may be integral with projection  416  and/or sleeve  428 . 
       FIG. 14  is a perspective view of another example sleeve  528  for use with any of the adapter bodies and coupling members disclosed herein. Sleeve  528  may include an axial hole or sound conduit  532 , which is similar to hole  32  described above in relation to sleeve  28 . Sleeve  528  may also include a mouth region  574  for connecting sleeve  528  to an adapter body or coupling member. For example, sleeve  528  may be attached to a coupling member or adapter body by disposing mouth  574  about the relevant structure. In addition, sleeve  528  may include one or more flaps or flanges  576 . In some embodiments, sleeve  528  may include one, two, three, four, five, or more flanges. Flanges  576  may be configured so that they can bend inward or fold over when disposed in the ear canal of a user. For example, one flange  576  may fold over an adjacent flange  576 . This feature may provide greater comfort for the user as well as the other sound-isolating and other desirable features described above. Sleeve  528  may be made from any suitable material. For example, sleeve  528  may be made from silicone rubber or any of the materials disclosed herein. 
     It should be understood that this disclosure is, in many respects, only illustrative. Changes may be made in details, particularly in matters of shape, size, and arrangement of steps without exceeding the scope of the invention. The invention&#39;s scope is, of course, defined in the language in which the appended claims are expressed.