Abstract:
A headset with removable ear pieces such that a user may interchange between ear gels and mushroom type ear pieces, or other pieces. The earpieces may be removably attached to the headset using a circular snap in some embodiments. An ear gel consisting of two types of elastomer of differing hardness, allowing for a soft elastomer to be in contact with the user&#39;s ear, giving greater comfort and better fit, the soft elastomer overmolded onto a firmer elastomer used to snap to the headset.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation-in-part of U.S. patent application No. 11/488,957 to Bevirt et al., filed Jul. 19, 2006, which is hereby incorporated by reference in its entirety. This application also claims priority to U.S. Provisional Patent Application No. 60/849,554, filed Oct. 4, 2006, to Bevirt et al. 
     
    
     BACKGROUND 
       [0002]    1. Field of the Invention 
         [0003]    This invention relates to headsets, and more specifically to headsets with differing types of earpieces. 
         [0004]    2. Description of Related Art 
         [0005]    Personal two way communications devices are becoming ever more popular. The use of cellular telephones is becoming more and more a part of everyday life, and the use of cordless telephone devices continues to increase. Also, the introduction of family radio services two way radios into the market place has greatly increased the popularity and usage of two way radios. 
         [0006]    It has long been known in the industry to use a headset for receiving sound from such two way communications devices. Such headsets may contain small speakers placed on or near one or both ears of the user for allowing the user to hear audio signals produced by the communications device. Such headsets may be used with a separate detached microphone, or may be used with a microphone attached thereto. The most common configuration for attached microphones is to place the microphone on a boom arm such that the microphone is near the mouth of the user. However, other configurations are known in the art, such as placing the microphone on a cord hanging from the speaker portion, or otherwise connecting the microphone to the headset mechanism. 
         [0007]    While many of the prior art headset devices have adequately produced sound to the user and received sound which is produced by the user, anyone who has used such devices knows that the ideal solution has yet to be produced in the prior art. Among the problems that have existed in the prior art are the fact that the sound producing devices of the headset often completely occlude the ear or ears of the user, thus inhibiting the user from hearing outside sounds. This can be inconvenient in certain situations. Another problem is that there can be cross talk between the speakers and the microphone. This is a particular problem where the speaker devices are non-occluding. In such arrangements the amount of sound escaping from the speaker devices is often sufficiently great that it can be picked up by the microphone. 
         [0008]    An additional problem with prior art devices is that while a user may select a headset based on its technical specifications, it may be limited in the size and type of earpiece that it is equipped with. Some users may want to use an earpiece of a particular type, size, shape, or softness, and they may also want to vary between types of earpieces depending upon the operating environment in which they are using the headset. Thus, a user may desire to have higher quality sound and to hear less background noise, yet in other situations may desire to hear more of their environment. One type of earpiece may provide more outside sound isolation and another may provide less outside sound isolation. Prior art devices have required the user to settle on a pre-determined balance of these factors. A headset which allows for the switching of earpieces of differing types would present a distinct improvement over the prior art. A user may select the earpiece best suited to their need while having needed to purchase only a single headset. 
         [0009]    What is needed is a headset that allows for the easy removal and replacement of earpieces such that differing types and sizes of earpieces, such as gel caps and mushroom caps, can be selected and installed by the user. What is also needed is a gel cap earpiece which is both soft and able to be removed and replaced. 
       SUMMARY 
       [0010]    A headset with easily removable and replaceable ear pieces such that a user may interchange between ear gels and mushroom type ear pieces, or other pieces. The earpieces may be removably attached to the headset using a circular snap in some embodiments. An ear gel consisting of two types of elastomer of differing hardness, allowing for a soft elastomer to be in contact with the user&#39;s ear, giving greater comfort and better fit, the soft elastomer overmolded onto a firmer elastomer used to snap to the headset. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS  
         [0011]      FIG. 1  illustrates a headset according to some embodiments of the present invention. 
           [0012]      FIG. 2  illustrates a headset according to some embodiments of the present invention. 
           [0013]      FIG. 3  illustrates an ear engaging body and speaker cap according to some embodiments of the present invention. 
           [0014]      FIG. 4  illustrates an ear engaging body and speaker cap according to some embodiments of the present invention. 
           [0015]      FIG. 5  is an exploded view of an earpiece according to some embodiments of the present invention. 
           [0016]      FIG. 6  is a cross-sectional view of an earpiece according to some embodiments of the present invention. 
           [0017]      FIG. 7  is an exploded view of an earpiece according to some embodiments of the present invention. 
           [0018]      FIG. 8  is a cross-sectional view of an earpiece according to some embodiments of the present invention. 
           [0019]      FIG. 9  is a sketch of an ear listing portions of the ear. 
           [0020]      FIGS. 10A-E  are views of an ear engaging body according to some embodiments of the present invention. 
           [0021]      FIG. 11  illustrates an ear and headset according to some embodiments of the present invention. 
           [0022]      FIG. 12  illustrates an ear and headset according to some embodiments of the present invention. 
           [0023]      FIG. 13  illustrates an ear and headset according to some embodiments of the present invention. 
           [0024]      FIGS. 14A-C  illustrate a speaker cap and a speaker cap with differing ear engaging bodies. 
           [0025]      FIGS. 15A-E  illustrate an ear engaging body according to some embodiments of the present invention. 
           [0026]      FIG. 16A-C  illustrates an ear and headset according to some embodiments of the present invention. 
       
    
    
     DETAILED DESCRIPTION  
       [0027]      FIGS. 1 and 2  illustrate a headset according to some embodiments of the present invention. The main body  151  may consist of an inner housing  153  and an outer housing  152 . An earpiece  159  is attached to the main body  151 . One or more buttons  151 ,  154  may be positioned on the outer housing  152  of the main body  151  and may be used to implement functionalities of the headset  150 . An LED panel  155  may indicate function. A microphone  156  is seen. The main body may contain the electronics for the headset or wireless headset. 
         [0028]    In some embodiments, the microphone may be a deployable microphone that deploys with the use of a microphone boom. The microphone boom may be stowed into the main body  151 . Although the present invention has been disclosed using embodiments of wireless headsets, other types of headsets including wired headsets may be utilized in other embodiments. 
         [0029]    Referring to  FIGS. 1 and 2 , the earpiece  159  consists of an earpiece base  157  and an ear engaging body  158 . The earpiece  159  may be attached to the main body  151  with a flexible joint. The flexible joint may allow the relative position and angle of the main body of the headset and the earpiece to be adapted for users with differing ear shapes and geometries. The ear engaging body  158  may be adapted to fit into the ear canal of the user, and may be adapted to support the headset on the user&#39;s head without additional attachments in some embodiments. 
         [0030]      FIGS. 3 and 4  illustrate aspects of removable and interchangeable ear engaging bodies according to some aspects of the present invention. In  FIG. 3 , a gel cap  206  is seen in exploded view with a speaker cap  201 . The gel cap  206  may be made of an elastomer with a hardness of shore A40-50 durometer. The speaker cap  201  provides the interface portion of the earpiece base to the gel cap  206 . The speaker cap  201  is seen with holes  203  which allow for the transmission of sound through the speaker cap  201 . A grip rim  202  presents a raised rim to which the gel cap  206  is removably attached to the speaker cap and thus the earpiece base. The gel cap  206  has an inner recess adapted to engage the grip rim  202 . The elastomer of the gel cap  206  is soft enough stretch over the grip rim as it is attached to the grip rim, yet stiff enough to remain affixed with the forces encountered with typical use of the headset, including the support of the headset by the ear via the gel cap. The removable nature of the gel cap  206  allows the user to substitute a cap of a size or shape more suited for the particular geometry of the user, or of a differing type of construction that may enhance or limit the ability of the ear in use to hear other sounds, or of a different hardness more suited to the comfort of the user. A gel cap typically does not seal the ear canal of the user. The user may prefer this type of ear engaging body, trading off the somewhat reduced sound quality for other concerns. Although some users may actually received an enhanced sound quality with a leaky gel cap. For those users, the sealed ear bud may create a diminished sound. 
         [0031]    In some embodiments of the present invention, as seen in exploded view in  FIG. 4 , a mushroom cap  200  is shown. The mushroom cap  200  is a different type of ear engaging body from the gel cap shown in  FIG. 3 . The mushroom cap  200  includes a circular cap  205  mounted onto a pyramid base  204  which is then removably attached to the speaker cap  201 . A flange  207  on the pyramid base  204  is inserted into a mating feature on the underside of the mushroom cap  205  to attach the two pieces. The mushroom cap  200  typically substantially seals off the ear canal of the user. This results in reduced outside noise and enhanced sound quality. 
         [0032]      FIG. 5  illustrates an exploded view of an earpiece according to some embodiments of the present invention. An earpiece base  211  provides a cavity and enclosure for the speaker  210 . The speaker cap  201  is affixed to the earpiece base  211  and covers and protects the speaker  210 , which sits in a well  221  within the top of the earpiece base  211 . A gel cap  206  is removably attached to the speaker cap  201 , which is affixed to the earpiece base  211 . In some embodiments, the earpiece base is connected to the main body of the headset with a flexible joint. In some embodiments, the flexible joint is a ball and socket joint. In some embodiments, the speaker may be on the main body side of the flexible joint and the sound may be channeled through the joint to the ear of the user. In some embodiments, the grip rim may be mounted on the headset, and the ear engaging bodies may be thus directly mounted to the headset. 
         [0033]      FIG. 6  is a cross-sectional view of an earpiece according to some embodiments of the present invention. The earpiece base  211  is seen with a socket receiving cavity  212  adapted to receive a socket to form a flexible joint with the main body of the headset. An internal lip  214  is adapted to function as a mechanical stop to prevent over-rotation of the socket, which may be hollowed out to allow the internal lip  214  to reside within the hollow, thus allowing only a predetermined range of rotation. A hole  213  through the base  211  allows for the routing of wires to a speaker (or other type of audio driver). In some embodiments, the speaker may be on the headset side of the joint, and the hole  213  may be adapted to channel sound across the joint. A speaker  210  resides within a cavity in the upper portion of the earpiece base  211 . The speaker cap  201  is attached to the earpiece base  211 , and provides both a physical interface to the ear engaging body, as well as a protective cover for the speaker. The gel cap  206  has a recess  215  adapted to engage the grip rim  202 , and an extension  216  adapted to clip under the grip rim  202 . Although a circular profile is illustrated, other shapes may be used. The bottom surface  214  of the gel cap  206  may overlay in part the top of the speaker cap  201  in some embodiments. A through channel  222  is adapted to channel sound through the gel bud  206 . In some embodiments, the gel cap  206  is of a TPE material, with a durometer of shoreA 10-50. In some embodiments, the gel cap  206  is of a TPE material, with a durometer of shore 25. 
         [0034]      FIG. 7  illustrates an exploded view of an earpiece according to some embodiments of the present invention. An earpiece base  211  provides a cavity and enclosure for the speaker  210 . The speaker cap  201  is affixed to the earpiece base  211  and covers and protects the speaker  210 , which sits in a well  221  within the top of the earpiece base  211 . A gel cap  220  is removably attached to the speaker cap  201 , which is affixed to the earpiece base  211 . In some embodiments, the earpiece base is connected to the main body of the headset with a flexible joint. In some embodiments, the flexible joint is a ball and socket joint. In some embodiments, the speaker may be on the main body side of the flexible joint and the sound may be channeled through the joint to the ear of the user. In some embodiments, the grip rim may be mounted on the headset, and the ear engaging bodies may be thus directly mounted to the headset. 
         [0035]    The gel cap  220  has an outer section  218  and an inner section  217 . The use of a two or multi part gel cap allows for a softer, potentially much more versatile and comfortable, gel cap. The outer section  218  may be of softer material, such as a TPE with shoreA 10-25 durometer. The inner section  217  may be of a somewhat firmer material, such as a TPE with shoreA 40-50. The softer outer section may be adapted for the comfort and fit of the user. The firmer inner section allows for sufficient rigidity such that the gel cap can be snapped on and off of the earpiece base, and of sufficient rigidity to stay snapped onto the earpiece base, when used in an interchangeable scenario according to some embodiments of the present invention. The gel cap  218  may be manufactured using an overmolding process that results in a unitary piece with the two materials as shown. 
         [0036]      FIG. 8  is a cross-sectional view of an earpiece according to some embodiments of the present invention. The earpiece base  211  is seen with a socket receiving cavity  212  to receive a socket to form a flexible joint with the main body of the headset. In some embodiments, the speaker may be on the headset side of the joint. A speaker resides within a cavity in the upper portion of the earpiece base  211 . The speaker cap  201  is attached to the earpiece base  211 , and provides both a physical interface to the ear engaging body, as well as a protective cover for the speaker. The gel cap  220  has a recess adapted to engage the grip rim  202 , and an extension adapted to clip under the grip rim  202 . The bottom surface of the gel cap  220  may overlay in part the top of the speaker cap  201  in some embodiments. A through channel is adapted to channel sound through the gel cap  220 . In some embodiments, the gel cap  220  is of two types of TPE material. The outer section  218  may be of a first material, and the inner section  217  may be of a second material. The outer section  218  may be of softer material, such as a TPE with shoreA 10-25 durometer. The inner section  217  may be of a somewhat firmer material, such as a TPE with shoreA 40-50. The softer outer section may be adapted for the comfort and fit of the user. The firmer inner section allows for sufficient rigidity such that the gel cap can be snapped on and off of the earpiece base, and of sufficient rigidity to stay snapped onto the earpiece base, when used in an interchangeable scenario according to some embodiments of the present invention. 
         [0037]      FIG. 9  is a sketch of a human ear with numerous of its features labeled. This sketch helps the reader to understand some of the terms used below. 
         [0038]      FIGS. 10A-E  illustrate a gel cap  300  according to some embodiments of the present invention. The gel cap  300  is an ear engaging body adapted to be removably attached to an ear piece base as described above. As seen in  FIG. 10A , the gel cap may be of an elliptical shape  301 . The view of  FIG. 10A  is a top view down parallel to Plane A of  FIG. 10D . The gel cap  300  may consist of a lower section, or neck  302 , which has a through hole  305  for the channeling of sound from the speaker to the ear of the user. The gel cap  300  has a recess  306  adapted to fasten the gel cap  300  to the grip rim of the ear piece base. The neck  302  expands into an elliptical upper section  303  which may have a flared edge  310 . A groove  304  is seen extending from the through hole  305  towards the raised end  307  of the gel cap  300  along the major elliptical axis. The bottom  309  of the neck may be substantially flat. 
         [0039]    As seen in  FIG. 11 , the major axis of the elliptical shape  301  is aligned when in use such that one end  307  is narrowed and pointed toward the ear canal, resting under the traqus  330 , and the opposite end  308  rests behind the anti-helix  331 . The minor axis of the ellipse is secured between the Crus and the antitraqus  332 . The crus is not labeled on the ear drawing. It is just below the crus helicus and is more or less horizontal across the mid part of the ear. The gel cap  300  is adapted to protrude into the ear canal but does not enter the ear canal and is not adapted to provide an ear seal. The groove  304  is provided in the surface of the gel cap facing the meatus extuemus and cavum conchae. The groove, which is designed in part to create a controlled sound leak,  304  is flared at its far end  312  to accommodate differing ear canal  333  locations for users of different ear geometry, and to allow the gel cap to be used in either ear. The groove and flare allow more flexibility in the channeling of sound into the ears of different users, enhancing sound transmission. In some embodiments, the through hole may be routed out to the end  307  of the gel cap within the cap itself, obviating the need for a groove. 
         [0040]      FIGS. 14A-C  illustrate a speaker cap according to some embodiments of the present invention. The speaker cap  400  is adapted to provide audio signal to a user. The main body  401  of the speaker cap  400  may have a speaker or other type of audio driver or device within it. An ear piece base  402  is attached to or part of the main body  401  of the speaker cap  400 . The ear piece base  402  is adapted to allow for the interchange of different ear engaging bodies with the speaker cap  400 . 
         [0041]      FIGS. 15A-E  illustrate a two piece gel cap according to some embodiments of the present invention. 
         [0042]      FIGS. 16  A-C illustrate a mushroom cap engaged in to the ear of a user according to some embodiments of the present invention. 
         [0043]    In some embodiments, the speaker cap  400  may be a wireless device adapted to receive signal from another electronic device. In some embodiments, the speaker cap may have electronics within it adapted to receive a wireless signal and to route it to the enclosed speaker. In some embodiments, the speaker cap may be a wired device. The speaker cap may be wired to another electronic device, such as a wireless headset, cellular telephone, entertainment device, or another type of device. 
         [0044]      FIGS. 14B and 14C  illustrate the speaker cap  400  with differing ear engaging bodies according to some embodiments of the present invention.  FIG. 14B  shows a gel cap  403  attached to the speaker cap  400 . The gel cap  403  is easily removable and attachable to the speaker cap  400 .  FIG. 14C  shows a mushroom cap  406  attached to the speaker cap  400 . The mushroom cap  406  may consist of a circular cap  404  and a pyramid base  405 . Prior art circular type caps typically have a permanently affixed base which only allows the replacement of one type of circular cap with another, but does not allow replacement with a gel type cap as described herein. 
         [0045]    As seen, the differing caps may be easily removed and replaced onto the speaker cap, allowing the user the flexibility of choosing which type of ear engaging body to use, depending upon personal preference or specific need, while maintaining the use of a single speaker cap. 
         [0046]    As evident from the above description, a wide variety of embodiments may be configured from the description given herein and additional advantages and modifications will readily occur to those skilled in the art. The invention in its broader aspects is, therefore, not limited to the specific details and illustrative examples shown and described. Accordingly, departures from such details may be made without departing from the spirit or scope of the applicant&#39;s general invention.