Patent Description:
Hearing protectors are typically used in noisy environments for protecting a wearer's hearing from noise at potentially harmful noise levels. Typically, hearing protectors have two muffs or caps which cover the ears of the wearer and which are connected to one another by a headband. Each cup further typically is formed by a rigid shell that is furnished with a noise dampening material, for example a foamed material.

There is a general desire to make hearing protectors user-friendly, in particular to encourage persons that are in noisy environments for longer times to actually wear the protectors. While noise dampening is the essential purpose of a hearing protector, there is often a need for the wearer to hear certain sounds from the environment, like acoustic signals, instructions, or conversations. Further, there is often a desire for the wearer to use the hearing protector as headset for radio or telephone applications.

There are active hearing protectors on the market which have passive noise dampening properties and additionally are configured to transmit sounds from the environment into the ear cup via active electronics connected to a microphone outside the ear cup and a loud speaker inside the ear cup. Such hearing protectors are typically set up so that the active sound transmission is restricted to a pre-determined level with respect to the human hearing. Sound levels from the environment that exceed that pre-determined level are dampened due to the passive dampening properties of the hearing protector.

<CIT> for example discloses a hearing protector device including a sound attenuating body and an electronic unit having a microphone, an amplifier, and a loudspeaker, where the electronic unit is selectively activated and, when activated, receives sound from an ambient environment, amplifies a frequency range of the received sound corresponding to a frequency range of human speech, and varies said amplification such that a total level of sound passing through the body and through the electronic unit does not exceed a maximum predetermined sound level. discloses a hearing protector comprising a hearing hood, a microphone, a loudspeaker and an amplifier. The hearing hood has passive noise damping. The microphone is disposed exteriorly on the hearing protector, while the loudspeaker is disposed inside the hood. The amplifier amplifies and transmits the signals from the microphone to the loudspeaker. The noise damping of the hearing hood is broad band.

<CIT> discloses a quick release speaker system.

Although existing active hearing protectors have a variety of advantages there is still a need for a hearing protector which is of preferably high quality and durable but relatively inexpensive. Further, such a hearing protector desirably can be serviced relatively conveniently.

This disclosure relates to a hearing protector having an ear cup forming a space for a wearer's ear. In particular, the disclosure relates to the ear cup. The ear cup comprises a shell having an ear facing inner side and a passageway extending through the shell between the ear facing inner side and an outer side of the shell. The ear cup further comprises a loudspeaker assembly which seals the passageway from the outer side. The loud speaker assembly comprises a seal member and a loudspeaker module, wherein at least a (preferably circumferential) portion of the seal member is arranged between the shell and a fastener which retains the loudspeaker assembly at the shell.

The design may be advantageous in that it provides a hearing protector which is relatively comfortable to wear. Further the design may be advantageous in that it provides a hearing protector which is relatively reliable in use. The hearing protector may further be manufactured at relatively low costs.

The shell of the ear cup generally has an ear facing end and an opposite rear end that faces away from a wearer's ear (when the hearing protector is worn). The ear facing inner side is typically arranged adjacent the ear facing end. A ring-shaped cushioning is preferably arranged adjacent the ear facing end. Further a noise absorber pad is arranged between the cushioning and the ear facing inner side of the shell. The shell may be furnished with alternative or additional noise absorber means. The cushioning and the noise absorber pad in combination preferably provide the space for the wearer's ear.

The cushioning comprises a soft and resilient core material, for example a foamed plastic material and is preferably covered by a sheath. The sheath may be made of a soft film material that is optionally generally non-permeable relative to moisture. The cushioning provides for the ear cup to seal at a wearer's head so as to hermetically encapsulate the space around the wearer's ear. Thus, a so-called passive noise dampening or attenuation is provided by the ear cup.

According to the present disclosure, the loudspeaker module is preferably arranged at the outer side of the shell. It has been found that in such an arrangement the reliability of the loudspeaker module can be maximized. Although hearing protectors are often used in harsh environments so that there is a general desire to accommodate electronic components preferably inside the shell, it has been found that the arrangement on the outside has certain advantages. In particular, the outside arrangement provides for the loudspeaker module to be protected from moisture that may be in the air of the encapsulated space provided by the ear cup, for example due to sweating of the wearer during wearing of the hearing protector. Further, the outside arrangement prevents the loudspeaker module from heating up the air in encapsulated space.

In one embodiment the seal member forms a cavity. The loudspeaker is preferably accommodated in this cavity. The cavity is dimensioned so that the loudspeaker module fills a partial volume of the cavity but a further partial volume of the cavity provides a sound volume. The sound volume allows for determining a frequency profile of the sound provided by the loudspeaker assembly.

In a further embodiment the seal member is shaped as a tray. In particular, the seal member has a circumferential side wall and a base wall. The base wall forms an ear facing end of the seal member. The seal member further forms an open end opposite of the ear facing end.

In a further embodiment the seal member has an aperture through the seal member. The loudspeaker module preferably closes the aperture. Preferably, the passageway in the shell and the aperture in the seal member overlap. In particular the aperture and the passageway are preferably in fluid communication.

In a further embodiment the fastener sealingly covers the open end of the seal member. In particular, the fastener may hermetically seal or cover the partial cavity forming the sound volume. The fastener may have at least one through-hole in fluid communication with the sound volume. Thus, the hearing protector may be used at different environmental pressure conditions (for example at different altitudes) without affecting the sound frequency profile of the loudspeaker assembly. This is because air can exchange between the sound volume and the exterior.

In one embodiment the seal member tapers from the open end toward the ear facing end. This enables for play-free and thus accurately fitting of the seal member in a correspondingly shaped structure (for example a recess) in the shell.

In a further embodiment the shell of the ear cup has a compartment which opens in a direction away from the ear space. The seal member is preferably arranged at least partially within the compartment. The compartment may comprise a recess (as mentioned) that is shaped in accordance with a negative shape of the seal member. Thus, the seal member may be positioned within the recess so that the aperture and the passageway overlap or coincide.

The fastener comprises electronic circuitry. The fastener further comprises first electrical contacts for contacting with the loudspeaker module. In the hearing protector one or both of the ear cups may have electronic circuitry. Preferably, only one of the ear cups comprises the electronic circuitry (in addition to the loudspeaker module) and the other one of the ear cups is connected to this electronic circuitry. The fastener may for example comprise a printed circuit board or may itself be formed of a printed circuit board.

The loudspeaker module comprises second electrical contacts. The first and second electrical contacts are in releasable contact with each other. The first and/or second electrical contacts may be formed as spring contacts. Thus, a reliable contact can be ensured over a relatively long time. In a preferred embodiment the second electrical contacts are spring contacts and the first electrical contacts are contact pad which the spring contacts contact. Each of the first and second contacts may have a gold coating. The gold coating prevents oxidation of the contacts and minimizes the contact resistance. The loudspeaker module further comprises a loudspeaker, for example a dynamic or an electrodynamic loudspeaker.

In one embodiment the hearing protector comprises a battery. The battery provides for powering any electronic functionality of the hearing protector. The hearing protector may for example have a so-called "listening mode capability". The listing mode capability allows a wearer of the hearing protector to hear sounds from the environment without removing the hearing protector. The sounds provided by the loudspeaker are limited to a maximum noise level of <NUM> dB (decibels), meaning that the sounds provided by the loudspeaker are within a noise level range of <NUM> dB to <NUM> dB but not outside that range. For the listening mode capability the electronic circuitry is configured for amplifying sound signals picked up by a microphone from an area outside of the ear cup. The hearing protector may further have a knob or push button for the wearer to selectively activate and deactivate the listening mode. The hearing protector may further be configured for radio operation, for example may be connectable or connected to a radio equipment, mobile phone, MP3-player or the like. Such radio operation function may be built-in or provided from external. In the latter case the hearing protector may have a wired or wireless interface (preferably Bluetooth®) for connection with the external device.

In one embodiment the hearing protector has two ear cups being suspended at a headband. The headband is preferably resilient and configured to urge the ear cups toward a wearer's head when the hearing protector is worn.

In a further aspect, the disclosure relates to a method of assembling an ear cup for a hearing protector. The ear cup forms a space for a wearer's ear. The method comprises the steps of:.

In an example the method further comprises the step of pre-assembling the loudspeaker assembly. The loudspeaker module and the seal member thereby may be assembled so that they are retained with each other. This allows for handling the loudspeaker assembly as one piece, for example during manufacturing of the hearing protector.

The fastener may comprise electronic circuitry and first electrical contacts for contacting with the loudspeaker module and the loudspeaker module may comprise second electrical contacts. In a further embodiment the step of retaining the loudspeaker module causes the first and second electrical contacts to get into releasable contact with each other. Therefore separate contacting, for example by soldering or welding, is not required.

<FIG> shows a hearing protector <NUM>, in accordance with this disclosure. The hearing protector has two ear cups <NUM>. It is noted that the same numbering (<NUM>) used to designate both ear cups does not imply that the ear cups must be identical in every detail, although they can be identical in every detail. In fact, in the present example the two ear cups include certain components that are technically identical and other components that are different as described in the following. The ear cups <NUM> are suspended at a common headband <NUM>. The headband <NUM> is resilient and configured to gently urge the ear cups <NUM> toward a wearer's head when the hearing protector is worn. Further, one of the two ear cups may have additional or fewer components than the other one. The ear cup <NUM> has a shell <NUM>. In the example the shell <NUM> is made of a plastic material. The plastic material preferably is generally rigid. Suitable materials are selected from among acrylonitrile-butadiene-styrene terpolymer (ABS), polypropylene (PP), polyethelene (PE), polycarbonate (PC), a blend thereof, and preferably acrylonitrile-butadiene-styrene terpolymer (ABS). Other plastic materials providing the desired rigid structure may be used as appropriate. Each ear cup <NUM> further has a cushioning <NUM>. The cushioning <NUM> comprise a soft, preferably elastically deformable material. In the example, the cushioning comprises a foamed polyurethane (PU) core covered by a polyvinylchloride (PVC) sheath. Other materials may be used as appropriate. The cushioning <NUM> is configured to adapt to a wearer's head in an area around the wearer's ear, so as to form a preferably air-tight seal at this area. Further, the cushioning <NUM> is ring-shaped and thus provides at least part of a space <NUM> for the wearer's ear. The ear cup <NUM> (in interaction with the wearer's head) encapsulates that ear space <NUM> from the environment by means of at least the cushioning <NUM> and the shell <NUM>. Each ear cup <NUM> further has a noise absorber pad <NUM>. The noise absorber pad <NUM> is preferably made of a foamed material, for example a foamed PU material. The noise absorber pad <NUM> is preferably retained between the cushioning <NUM> and an ear facing inner side <NUM> (indicated in <FIG>) of the shell <NUM>. It is noted that the term "ear facing inner side" refers to the side of the shell that faces a wearer's ear during normal use of the hearing protector. The cushioning <NUM> and the shell <NUM> are preferably removably retained with each other, for example by a snap connection. The noise absorber pad <NUM> may be clamped between the cushioning <NUM> and the shell <NUM>. Therefore, the cushioning <NUM> and the noise absorber pad <NUM> are exchangeable, for example for the purpose of maintenance or for changing the noise absorbing properties of the hearing protector <NUM>.

Referring to <FIG> the shell <NUM> has an outer side <NUM> which comprises the side which faces in a direction opposite of the ear facing inner side <NUM> and adjacent lateral sides that face outward. In certain embodiments the outer side <NUM> may, however, only include the side which faces in a direction opposite of the ear facing inner side <NUM>. In the example each ear cup <NUM> has a loudspeaker module <NUM>. The loudspeaker module <NUM> serves for emitting sounds into the ear space <NUM> so that a wearer of the hearing protector <NUM> can recognize these sounds despite the noise dampening effect provided by the ear cup <NUM>. The hearing protector <NUM> as shown in the example may have a listening mode and/or a radio capability. For the listening mode and/or radio capability the hearing protector <NUM> further has electronic circuitry <NUM> for amplifying sound signals, for example picked up by a microphone (not shown) or transmitted to the electronic circuitry <NUM> otherwise. A knob or push button (not shown) may be provided for the wearer to selectively activate and deactivate the listening mode and or radio. The loudspeaker module <NUM> is assembled to the shell <NUM> by use of a seal member <NUM>. In particular, the loudspeaker module <NUM> is arranged within the seal member <NUM> in an area on the outer side <NUM> of the shell <NUM>. The seal member <NUM> and the loudspeaker <NUM> in combination form a loudspeaker assembly <NUM>, which can be handled in one piece during manufacturing and maintenance of the hearing protector <NUM>. The seal member is preferably made of a silicone material. The silicone material is softer than the material of the shell <NUM> and resilient. While the skilled person is aware of other soft and resilient materials, silicone has proven to be relatively durable, in particular if kept under a compression force over a long time period.

The hearing protector <NUM> has further a fastener <NUM> in each of the ear cups <NUM> for retaining the respective loudspeaker assembly <NUM> at the shell <NUM>. In the example at least one of the fasteners comprises the electronic circuitry <NUM> and is in the form of a printed circuit board. The shell <NUM> on the outer side <NUM> forms a compartment <NUM> which opens in a direction opposite of the direction in which the ear facing inner side <NUM> faces. The compartment <NUM> is configured for accommodation of the loudspeaker module <NUM>, the seal member <NUM>, the electronic circuitry <NUM> and optionally for further components. Each ear cup <NUM> further has a cover <NUM> for closing the compartment <NUM> so as to encapsulate the components accommodated therein.

<FIG> shows the loudspeaker assembly <NUM> in more detail. The loudspeaker assembly <NUM> has the loudspeaker module <NUM> and the seal member <NUM>.

The loudspeaker module <NUM> has electrical contacts <NUM> (also referred to as second electrical contacts herein). In the example the loudspeaker module has two electrical contacts <NUM>. Although the same reference number (<NUM>) is used for ease of explanation, the two electrical contacts <NUM> of the loudspeaker module <NUM> are mechanically identical but have electrically different functions. The skilled person will be able to select an appropriate loudspeaker module from a variety of loudspeaker modules on the market, including loudspeaker modules having more than two electrical contacts.

The seal member <NUM> is formed as a tray that has a stepped base wall <NUM> and a circumferential side wall <NUM>. The stepped configuration of the base wall is preferred, but optional. In accordance with its desired orientation in the hearing protector the base wall <NUM> is designated to form an "ear facing end" <NUM> of the seal member <NUM>. The end opposite of the ear facing end <NUM> is open and therefore is referred to as "open end" <NUM>. The open end <NUM> is planar which forms a first sealing surface <NUM> which in the example is planar too. In other words, at the open end <NUM> the side wall <NUM> forms a circumferential free end that extends in a plane. The person skilled in the art will recognize that the first sealing surface may have other shapes than planar. For example the sealing surface may be formed as a bulge or ridge extending circumferentially parallel to a plane. The seal member <NUM> further forms a second sealing surface <NUM>. The sealing surface <NUM> in the example is formed by outer surfaces of the base wall <NUM> and the side wall <NUM>. It is noted that the side wall <NUM> tapers from the open end <NUM> toward the ear facing end <NUM>.

<FIG> shows the loudspeaker assembly <NUM> assembled in the shell <NUM>. The shell <NUM> has a passageway <NUM> extending through the shell <NUM>. The passageway <NUM> extends in particular between the ear facing inner side <NUM> and the outer side <NUM> of the shell. The loudspeaker assembly <NUM> seals the passageway <NUM> from the outer side <NUM>. In particular, the loudspeaker assembly <NUM> blocks the passageway <NUM> and is removable only in a direction from the ear facing inner side <NUM> toward the outer side <NUM> of the shell. Accordingly, the loudspeaker assembly <NUM> can be assembled only in a direction from the outer side <NUM> of the shell the ear facing inner side <NUM> toward the ear facing inner side <NUM>. This enables the loudspeaker assembly and/or the loudspeaker module <NUM> to be assembled or exchanged in a situation which other components of the ear cup (for example the noise absorber pad and the cushioning) are already assembled at the shell <NUM>.

As described in <FIG> the shell forms a compartment <NUM> (not entirely illustrated in this view) at the outer side <NUM> of the shell <NUM>. The compartment <NUM> comprises a recess <NUM> which is shaped in accordance to a negative outer shape of the seal member <NUM> (or at least a portion thereof). Further, the passageway <NUM> is provided within the recess <NUM>. Accordingly, the seal member <NUM> is (snugly) fit into the recess <NUM>. And thus, the seal member <NUM> - and therefore the loudspeaker assembly <NUM> - are appropriately positioned relative to the passageway <NUM>. The seal member <NUM> due to the fit within the recess forms a seal in the recess. Further, the shell has a sealing bulge <NUM>. The sealing bulge <NUM> is located on the outer side <NUM> of the shell <NUM>. The sealing bulge <NUM> further entirely surrounds an opening <NUM> of the passageway <NUM>. The sealing bulge <NUM> is in a sealing contact with the second sealing surface <NUM>.

Further, the seal member <NUM> has an aperture <NUM>. The aperture <NUM> overlaps with the passageway <NUM> in the situation in which the seal member <NUM> is fitted in the recess <NUM>. The aperture <NUM> in the example is closed by the loudspeaker module <NUM>. In particular, the loudspeaker module <NUM> closes the aperture <NUM> such that a sound emitting portion of the loudspeaker module <NUM> faces and overlaps with the aperture <NUM>. Accordingly, any sound emitted by the loudspeaker module <NUM> is emitted toward a wearer's ear when the hearing protector is worn. It is noted that the skilled person is aware that the passageway <NUM> and the aperture <NUM> may in certain examples not be entirely open but may be spanned or provided with a sound permeable material, for example a foamed, woven or non-woven material or a membrane.

As shown, the loudspeaker module <NUM> is located outside a room <NUM> that is enclosed or defined by the ear facing inner side of the shell <NUM>. This prevents that any heat generated by the loudspeaker module <NUM> does not heat up the air around the wearer's ear. Further, this prevents that any moisture, for example due to sweating of the wearer does not easily reach electrical contacts or wires of the loudspeaker module. Accordingly, the arrangement of the loudspeaker module <NUM> on the outside of the shell <NUM> helps maximizing the wearing comfort and technical reliability of the hearing protector.

The loudspeaker assembly <NUM> is retained at the shell via the fastener <NUM>. In particular, the fastener <NUM> and the shell <NUM> are retained with each other and clamp the seal member <NUM> between. Thereby, a circumferential portion of the seal member <NUM> is arranged between the shell <NUM> and the fastener <NUM>. That circumferential portion of the seal member <NUM> further surrounds the passageway <NUM>.

In the example the fastener <NUM> further comprises electronic circuitry (indicated in <FIG>). In particular the electronic circuitry comprises first electrical contacts (not particularly illustrated but indicated by reference number <NUM>). The ear cup (with the shell <NUM>, the loudspeaker assembly <NUM>, and the fastener <NUM>) is configured so that the first electrical contacts <NUM> meet with the second electrical contacts <NUM> of the loudspeaker module <NUM> when the shell <NUM>, the loudspeaker assembly <NUM>, and the fastener <NUM> are assembled. Further, in the example the fastener <NUM> and the shell <NUM> clamp the loudspeaker assembly <NUM> between. Thus, the loudspeaker assembly <NUM> is retained in the ear cup under tension. Preferably, thereby also the first and second electrical contacts <NUM>, <NUM> are held in contact with each other. The first and second electrical contacts <NUM>, <NUM> are preferably contacted in a releasable contact relationship with each other. Therefore, for example no soldering or welding is required. Further, the first and second electrical contacts <NUM>, <NUM> are selectively separable from each other as desired, for example during an exchange of the loudspeaker module <NUM>.

Claim 1:
A hearing protector (<NUM>) having an ear cup (<NUM>) forming a space for a wearer's ear, the ear cup (<NUM>) comprising a shell (<NUM>) having an ear facing inner side (<NUM>) and a passageway (<NUM>) extending through the shell (<NUM>) between the ear facing inner side (<NUM>) and an outer side (<NUM>) of the shell (<NUM>), the ear cup (<NUM>) further comprising a loudspeaker assembly (<NUM>) which seals the passageway (<NUM>) from the outer side (<NUM>), the loud speaker assembly (<NUM>) comprising a seal member (<NUM>) and a loudspeaker module (<NUM>), wherein a portion of the seal member (<NUM>) is arranged between the shell (<NUM>) and a fastener (<NUM>) which retains the loudspeaker assembly (<NUM>) at the shell (<NUM>), wherein the fastener (<NUM>) comprises electronic circuitry (<NUM>) and first electrical contacts (<NUM>) for contacting with the loudspeaker module (<NUM>), and wherein the loudspeaker module (<NUM>) comprises second electrical contacts (<NUM>), and wherein the first and second electrical contacts (<NUM>, <NUM>) are in releasable contact with each other.