PATENT DOCUMENT

Publication Number: US-10237640-B2
Application Number: US-201715431368-A
Country: US
Kind Code: B2

Title: Deformable ear tip for earphone and method therefor

Abstract:
A removable component for use with an earphone is disclosed. As an example, the removable component can be an ear tip. According to one aspect, an improved ear tip can be provided for use with a headphone. The ear tip is suitable for in-ear operation and can have a cosmetic deformable outer member. The deformable outer member can enable the ear tip to readily conform to a user&#39;s ear. The ear tip can also include an inner member to structurally support the outer member and to facilitate attachment to a headphone. Methods for forming such ear tips are also disclosed.

Claims:
What is claimed is: 
     
       1. An ear piece for an audio component housing, the ear piece comprising:
 an inner structure extending between an inner structure front end and an inner structure rear end; and 
 an outer structure extending between an outer structure front end and an outer structure rear end, wherein:
 a first portion of the outer structure is one of integrally formed with or coupled to the inner structure front end; 
 the inner structure comprises an attachment feature that is configured to at least partially couple the inner structure to the audio component housing within an audio passageway defined by the inner structure; 
 a portion of the attachment feature is positioned at a first distance along the inner structure from the inner structure front end; and 
 a second portion of the outer structure is one of integrally formed with or coupled to a portion of the inner structure that is positioned at the first distance along the inner structure from the inner structure front end. 
 
 
     
     
       2. The ear piece of  claim 1 , wherein the portion of the attachment feature is positioned at a second distance along the inner structure from the inner structure rear end. 
     
     
       3. The ear piece of  claim 1 , wherein the first portion of the outer structure comprises the outer structure front end. 
     
     
       4. The ear piece of  claim 1 , wherein the attachment feature is configured to at least partially mechanically secure the inner structure to the audio component housing. 
     
     
       5. The ear piece of  claim 1 , wherein the attachment feature comprises at least one recess in the inner structure. 
     
     
       6. The ear piece of  claim 1 , wherein a third portion of the outer structure is one of integrally formed with or coupled to the inner structure rear end. 
     
     
       7. The ear piece of  claim 6 , wherein the third portion of the outer structure is positioned at a distance along the outer structure from the outer structure rear end. 
     
     
       8. The ear piece of  claim 1 , wherein:
 the inner structure comprises an inner structure interior surface extending between the inner structure front end and the inner structure rear end; 
 the inner structure interior surface defines the audio passageway; 
 the inner structure comprises an inner structure exterior surface extending between the inner structure front end and the inner structure rear end; 
 the inner structure interior surface comprises the attachment feature; and 
 the inner structure exterior surface comprises the portion of the inner structure. 
 
     
     
       9. The ear piece of  claim 8 , wherein:
 the outer structure comprises an outer structure interior surface extending between the outer structure front end and the outer structure rear end; 
 the outer structure comprises an outer structure exterior surface extending between the outer structure front end and the outer structure rear end; and 
 the outer structure interior surface comprises the second portion of the outer structure. 
 
     
     
       10. The ear piece of  claim 1 , wherein:
 an air interface exists between a third portion of the outer structure and another portion of the inner structure; and 
 the third portion of the outer structure is configured to deform within the air interface during in-ear usage. 
 
     
     
       11. The ear piece of  claim 1 , wherein the outer structure is softer than the inner structure. 
     
     
       12. The ear piece of  claim 1 , wherein the inner structure is more rigid than the outer structure. 
     
     
       13. An ear piece for an audio component housing, the ear piece comprising:
 an inner structure extending between an inner structure front end and an inner structure rear end; and 
 an outer structure extending between an outer structure front end and an outer structure rear end, wherein:
 a first portion of the outer structure is one of integrally formed with or coupled to the inner structure rear end; 
 the inner structure comprises an attachment feature that is configured to at least partially couple the inner structure to the audio component housing within an audio passageway defined by the inner structure; 
 a portion of the attachment feature is positioned at a first distance along the inner structure from the inner structure rear end; and 
 a second portion of the outer structure is one of integrally formed with or coupled to a portion of the inner structure that is positioned at the first distance along the inner structure from the inner structure rear end. 
 
 
     
     
       14. The ear piece of  claim 13 , wherein the portion of the attachment feature is positioned at a second distance along the inner structure from the inner structure front end. 
     
     
       15. The ear piece of  claim 13 , wherein the first portion of the outer structure comprises the outer structure rear end. 
     
     
       16. The ear piece of  claim 13 , wherein the first portion of the outer structure is positioned at a distance along the outer structure from the outer structure rear end. 
     
     
       17. The ear piece of  claim 13 , wherein the attachment feature is configured to at least partially mechanically secure the inner structure to the audio component housing. 
     
     
       18. The ear piece of  claim 13 , wherein the attachment feature comprises at least one recess in the inner structure. 
     
     
       19. The ear piece of  claim 13 , wherein a third portion of the outer structure is one of integrally formed with or coupled to the inner structure front end. 
     
     
       20. An ear piece for an audio component housing, the ear piece comprising:
 an inner structure extending between an inner structure front end and an inner structure rear end; and 
 an outer structure extending between an outer structure front end and an outer structure rear end, wherein:
 the outer structure front end is one of integrally formed with or coupled to the inner structure front end; 
 the outer structure rear end is one of integrally formed with or coupled to the inner structure rear end; 
 the inner structure comprises an attachment feature that is configured to at least partially couple the inner structure to the audio component housing within an audio passageway defined by the inner structure; 
 a portion of the attachment feature is positioned at a first distance along the inner structure from the inner structure front end; 
 the portion of the attachment feature is positioned at a second distance along the inner structure from the inner structure rear end; 
 a portion of the outer structure is one of integrally formed with or coupled to a portion of the inner structure; 
 the portion of the inner structure is positioned at the first distance along the inner structure from the inner structure front end; and 
 the portion of the inner structure is positioned at the second distance along the inner structure from the inner structure rear end.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 14/886,491 filed Oct. 19, 2015 (now U.S. Pat. No. 9,571,912), which is a continuation of U.S. patent application Ser. No. 13/591,116 filed Aug. 21, 2012 (now U.S. Pat. No. 9,167,336), which is a continuation of U.S. patent application Ser. No. 12/794,690 filed Jun. 4, 2010 (now U.S. Pat. No. 8,280,093), which claims the benefit of priority of U.S. Provisional Patent Application No. 61/240,582 filed Sep. 8, 2009 and U.S. Provisional Patent Application No. 61/230,065 filed Jul. 30, 2009, and which is a Continuation-In-Part of U.S. patent application Ser. No. 12/205,748 filed Sep. 5, 2008 (now U.S. Pat. No. 8,270,656), which claims the benefit of priority of U.S. Provisional Patent Application No. 60/999,660 filed Oct. 19, 2007. Each of these earlier applications is incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     Several different approaches can be used to provide audio from an electronic device to a user. For example, the electronic device may include or be coupled to a speaker or speaker system operative to provide audio. As another example, the electronic device may be coupled to a headset or headphone for providing audio directly to the user&#39;s ears. A headset or headphone (or earphone) is a device that converts electric signals, such as from an electronic device, to audible sound and fits over or in a user&#39;s ear. Headphones come in various types and configurations. One type of headset or headphone is over-the-ear, and another type of headset or headphone is in-ear. 
     To improve a user&#39;s comfort, a headset or headphone may include one or more elements operative to provide a pleasant interface between the audio components of the headset (e.g., the ear piece) and the user&#39;s ears. For example, some headsets or headphones may include an over-the-ear type ear piece that is operative to be placed on or over the user&#39;s ear. The ear piece may include one or more foam or cloth components that provide a compliant fit against the user&#39;s ear. As another example, some headsets or headphones may include an in-the-ear type ear piece (e.g., an ear bud) operative to fit inside the user&#39;s ear. 
     In-ear headsets or headphones offer superior audio performance. Unfortunately, however, in-ear headsets or headphones have difficultly providing a proper fit with a user&#39;s ear while also being comfortable while being worn. 
     SUMMARY 
     The invention pertains to a removable component for use with an earphone. As an example, the removable component can be an ear tip and the ear tip can be at least partially deformable. 
     According to one aspect, the invention can pertain to an ear tip for use with a headphone. The ear tip can include a deformable outer member and is suitable for in-ear operation. The deformable outer member enables the ear tip to readily conform to a user&#39;s ear. The ear tip can also include an inner member to structurally support the outer member and to facilitate attachment to a headphone. The deformable outer member can be configured to deform around the inner member. The deformable outer member can be provided with a durable outer surface that can be cosmetically pleasing. 
     The invention may be implemented in numerous ways, including, but not limited to, as a system, device, apparatus, or method. Exemplary embodiments of the invention are discussed below. 
     As an ear tip for a headphone, one embodiment can include at least an inner cylindrical structure configured to removably attach to the headphone, and an outer spherical structure integral with or adhered to at least a top end and sides of the inner cylindrical structure. The outer spherical structure can be formed at least partially from a deformable material. The deformable material can also include a cosmetic surface. 
     As an ear tip for a headphone, another embodiment can include at least an inner cylindrical structure configured to removably attach to the headphone, and an outer spherical structure integral with or adhered to at least sides of the inner cylindrical structure. The outer spherical structure can be formed at least partially from a deformable material. The inner cylindrical structure can also extend substantially through the ear tip. 
     As an ear tip for a headphone, still another embodiment can include at least an inner cylindrical structure configured to removably attach to the headphone, and an outer rounded structure integral with or adhered to said inner cylindrical structure. The outer rounded structure being formed at least partially from a deformable material. The ear tip can also include an outer film provided around the outer spherical structure to provide an outer surface for the ear tip. 
     As a method for forming ear tips, one embodiment can include at least configuring a molding station having a top and bottom molding plates, first compression molding an inner structure using a first moldable material, and curing the formed inner structure. Thereafter, the method can include at least reconfiguring the molding station by replacing one of the top and bottom molding plates, second compression molding at least a portion of an outer structure using a second moldable material, and curing the at least a portion of the outer structure that has been formed by the second compression molding. The method can then conclude by removing a resulting ear tip from the molding station. 
     A method for forming ear tips, another embodiment can include at least configuring a molding station having a top and bottom molding plates, first compression molding an outer structure using a first moldable material, and curing the formed outer structure. Thereafter, the method can include at least reconfiguring the molding station by replacing at least one of the top and bottom molding plates, second compression molding at least a portion of an inner structure using a second moldable material, and curing the at least a portion of the inner structure that has been formed by the second compression molding. The method can then conclude by removing a resulting ear tip from the molding station. 
     As method for forming an ear tip, another embodiment can include at least providing an inner structure for an ear tip, providing a top mold having at least one protrusion, and providing a bottom mold having an ear tip cavity. The method can also include at least depositing a quantity of a second material into and/or adjacent the ear tip cavity, and coupling the top and bottom molds together with the protrusion being inserted into the cavity. Still further, the method can include at least curing the ear tip being formed within the cavity, and removing the formed ear tip from the bottom mold. 
     As a method for forming an ear tip, still another embodiment can include at least forming an inner structure for an ear tip, providing a top mold having at least one protrusion, and providing a porous bottom mold having an ear tip cavity. Further, the method can include placing a sheet of a first material over the cavity, wherein the sheet being used to form an outer film for the ear tip, depositing a quantity of a second material on the sheet and adjacent the cavity, and applying a vacuum to the porous bottom mold to draw the sheet of the first material and the at least a portion of the deposited second material into the cavity. In addition, the method can include placing the molded inner structure onto the protrusion, heating the cavity, and coupling the top and bottom molds together with the protrusion being inserted into the cavity. Still further, the method can include curing the ear tip being formed within the cavity. Following curing, the method can further include removing the top mold, removing excess portions of the first material and the second material, and removing the formed ear tip from the bottom mold. 
     As an ear tip for a headphone, one embodiment of the invention can, for example, include at least: an inner cylindrical structure configured to removably attach to the headphone; and an outer spherical structure integral with or adhered to a top end of the inner cylindrical structure but having an air interface between the outer spherical structure and the inner cylindrical structure at a bottom end. 
     As an ear piece for a headphone, one embodiment of the invention can, for example, include at least: an inner structure that provides structural support for the ear piece; and an outer structure integrally formed about the inner structure, the output structure being deformable so as to deform during in-ear usage. 
     As a method for forming deformable ear tips, one embodiment of the invention can, for example, include at least: configuring a first top molding plate and a first bottom molding plate at a molding station; first compression molding a plurality of inner structures using a first molding material and the configured first top molding plate and the first bottom molding plate; curing the inner structures that have been formed by the first compression molding; reconfiguring the molding station by replacing the first top molding plate with a second top molding plate; second compression molding a plurality of outer structures using a second molding material and the configured second top molding plate and the first bottom molding plate; curing the outer structures that have been formed by the second compression molding; and removing ear tips that have been formed from the molding plates. 
     As a method for forming deformable ear tips, another embodiment of the invention can, for example, include at least: configuring top and bottom molding plates at a molding station; first compression molding a plurality of inner structures using the configured top and bottom molding plates and a first molding material; curing the inner structures that have been formed by the first compression molding; reconfiguring the molding station by replacing one of the top and bottom molding plates; second compression molding a plurality of outer structures using a second molding material; curing the outer structures that have been formed by the second compression molding; and removing ear tips that have been formed from the molding plates. 
     Various aspects and advantages of the invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention will be readily understood by the following detailed description in conjunction with the accompanying drawings, in which: 
         FIGS. 1A-1B  are diagrams illustrating a headphone according to one embodiment of the invention. 
         FIGS. 2A-2C  are diagrams illustrating a headphone according to one embodiment of the invention. 
         FIG. 3  is a perspective view of a front body according to one embodiment of the invention. 
         FIG. 4  is a perspective assembly diagram for a front body assembly according to one embodiment of the invention. 
         FIG. 5  is a side view of a cap body according to one embodiment of the invention. 
         FIG. 6  is a cross-sectional view of a cap body according to one embodiment of the invention. 
         FIG. 7  is a cross-sectional view of an output portion of a front body according to one embodiment of the invention. 
         FIG. 8  is a cross-sectional view of a front body according to one embodiment of the invention. 
         FIGS. 9A-9E  are views of an ear tip according to one embodiment of the invention. 
         FIGS. 10A-10E  are views of an ear tip according to another embodiment of the invention. 
         FIGS. 11A-11E  are views of an ear tip according to still another embodiment of the invention. 
         FIG. 12  is a flow diagram of an ear tip formation process according to one embodiment of the invention. 
         FIG. 13  is a flow diagram of an ear tip formation process according to another embodiment of the invention. 
         FIG. 14  is a flow diagram of an ear tip formation process according to still another embodiment of the invention. 
         FIG. 15  is a cross-sectional representation of an ear tip which includes a plurality of layers according to an embodiment of the invention. 
         FIG. 16  is a flow diagram of an ear tip formation process according to yet another embodiment of the invention. 
         FIG. 17  illustrates an ear tip  1700  with an extended inner structure according to one embodiment of the invention. 
         FIG. 18  is a perspective view of an ear tip with an extended inner structure according to one embodiment of the invention. 
         FIG. 19A  is a rear view,  FIG. 19B  is a side view, and  FIG. 19C  is a cross-sectional view for an ear tip with an extended inner structure. 
         FIGS. 20A and 20B  illustrates a flow diagram of an ear tip formation process according to one embodiment. 
         FIGS. 21A-21G  are cross-sectional diagrams illustrating ear tip formation according to one embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The invention pertains to a removable component for use with an earphone. As an example, the removable component can be an ear tip and the ear tip can be at least partially deformable. 
     According to one aspect, the invention can pertain to an ear tip for use with a headphone. The ear tip can include a deformable outer member and is suitable for in-ear operation. The deformable outer member enables the ear tip to readily conform to a user&#39;s ear. The ear tip can also include an inner member to structurally support the outer member and to facilitate attachment to a headphone. The deformable outer member is configured to deform around the inner member. The deformable outer member can be provided with an outer cosmetic surface. 
     Exemplary embodiments of aspects of the invention are discussed below with reference to the various figures. However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes, as the invention extends beyond these embodiments. It should be noted that the embodiments are in many cases are not depicted in an actual or consistent scale. For example, embodiments are often depicted larger than actual product size for ease of illustration. 
       FIGS. 1A-1B  are diagrams illustrating a headphone  100  according to one embodiment of the invention.  FIG. 1A  is a side view of the headphone  100 , and  FIG. 1B  is a front view of the headphone  100 . The headphone  100  can also be referred to as an earphone. 
     The headphone  100  includes a front body  102  and a rear body  104 . The front body  102  is attached to the rear body  104 . Alternatively, the front body  102  and rear body  104  can be formed as a unitary structure. The headphone  100  can also include an ear tip  106 . The ear tip  106  is a deformable structure capable of conforming to a user&#39;s ear when being used by a user. The ear tip  106  can attach to a protruding portion  108  on the front body  102 . Still further, as illustrated in  FIG. 1B , the ear tip  106  can include an opening  110 . The opening  110  exposes a cover  112  provided on a top end of the protruding portion  108  of the front body  102 . As one example, the cover  112  can be a mesh cover, such as a screen (e.g., stainless steel screen). The top end of the protruding body  108  is adjacent the opening  110  in the ear tip  106 . To provide audio sound for the user, the headphone  100  provides an acoustic channel internal to the front body  102 . For proper output of quality audio sound from the headphone  100 , the acoustic channel needs to remain substantially free from foreign matter that may collect in the acoustic channel. By providing the cover  112  at the top end of the protruding body  108 , the cover  112  can serve to substantially prevent foreign matter, such as human debris (e.g., ear wax), from entering into the acoustic channel. 
       FIGS. 2A-2C  are diagrams illustrating a headphone  200  according to one embodiment of the invention.  FIG. 2A  is a perspective view of the headphone  200 ,  FIG. 2B  is a side view of the headphone  200 , and  FIG. 2C  is a front view of the headphone  200 . The headphone  200  includes a front body  202  and a rear body  204 . The front body  202  and the rear body  204  can be separately formed parts that can be assembled together to form a housing for the headphone  200 . In one implementation, the front body  202  is secured to the rear body  204  by mechanical features, such as notches, detents, recesses, threads, or adhesives. In another implementation, the front body  202  and the rear body  204  can be formed as a unitary structure. 
     The front body  202  includes a removable cap  206 . The removable cap  206  can include a plurality of the knurls  208 . In this embodiment, it is intended that the removable cap  206  be removable from the headphone  200  by a user. Hence, the knurls  208 , if provided, can assist the user with removal of the removable cap  206  from the headphone  200  or attachment of the removable cap  206  to the headphone  200 . As shown in  FIGS. 2A and 2B , the removable cap  206  can be removably attached to a top end of a protruding portion  210  of the front body  210 . 
     The front body  202  encloses an acoustic channel that is used to provide sound to a user of the headphone  200 . As such, acoustic channel extends through the center of the front body  202 . Further, the removable cap  206  includes a central opening so that the sound being provided via the acoustic channel can emit from the headphone  200 . As shown in  FIG. 2C , the headphone  200  can also include a mesh cover  212  provided on or within the removable cap  206 . Advantageously, the mesh cover  212  is placed at the end of the acoustic channel with respect to the front body  202 . The mesh cover  212  is thereby able to substantially prevent foreign matter, such as human debris, from entering into the acoustic channel. If significant foreign matter is able to enter the acoustic channel, the acoustical characteristics and the ability for the headphone  200  to properly output sound to its user can be substantially hindered. Hence, the mesh cover  212  serves to substantially block foreign matter from entering the acoustic channel. If the mesh cover  212  becomes clogged, the removable cap  206  can be removed from the front body  202  and the mesh cover  212  can be serviced (e.g., cleaned to remove accumulated foreign debris). 
     The front body  202 , the rear body  204 , the removable cap  206  and the mesh cover  212  can be formed of the same or different materials (e.g., plastic, ceramic, metals, nylon, etc.). In one implementation, the rear body  204  can be plastic, and the front body  202 , the removable cap  206  and the mesh cover  212  can be metal (e.g., stainless steel). 
       FIG. 3  is a perspective view of the front body  300  according to one embodiment of the invention. The front body  300  is, for example, suitable for use as the front body  202  illustrated in  FIGS. 2A-2C . 
     The front body  300  includes a base portion  302  and an output portion  306 . The base portion  302  can be integrally formed with the output portion  306 . Alternatively, the base portion  302  and the output portion  306  can be separate parts that are assembled together to form the front body  300 . A bottom end of the base portion  302  includes an opening  304 . The opening  304  allows the front body  300  to be attached to a rear body, such as the rear body  104  illustrated in  FIGS. 1A and 1B  or the rear body  204  illustrated in the  FIGS. 2A-2C . In addition, the front body  300  can include a removable cap  308 . The removable cap  308  can attach to the output portion  306 . As shown in  FIG. 3 , the removable cap  308  is able to be attached to a top end of the output portion  306 . 
       FIG. 4  is a perspective assembly diagram for a front body assembly  400  according to one embodiment of the invention. The front body assembly  400 , once assembled, can pertain to the front body  700  illustrated in  FIG. 3 . 
     The front body assembly  400  includes a front body  402 . The front body  402  includes a base portion  404  and an output portion  406 . The output portion  406  can correspond to a protruding portion of the front body  402 . As illustrated in  FIG. 4 , at the end of the protruding portion of the output portion  406 , various components can be inserted in or attached to the output portion  406 . Specifically, as shown in  FIG. 4 , an internal mesh  408  can be placed internal to an opening  409  of the output portion  406 . In addition, an internal gasket  410  can be placed within the opening  409  of the output portion  406 . The output portion  406  can also receive a cap body  412 . In one embodiment, the cap body  412  includes threads  414 . The opening  409  in the output portion  406  can also include threads. In such case, the cap body  412  can be screwed into the opening  409  in the output portion  406 . When the cap body is screwed into the opening  409  in the output portion  406 , the internal gasket  410  can serve to further secure the cap body  412  within the opening  409  of the output portion  406 . The internal gasket  410  can provide a compliant surface that can be compressed when the cap body  412  is screwed completely into the opening in the output portion  406 . The internal mesh  408  can be secured within the opening  409  in the output portion  406  by adhesive and/or by the internal gasket  410 . The internal gasket  410  can be sized such that even with the cap body  412  removed from the opening  409  in the output portion  406 , the internal mesh  408  remains secured in the opening  409 . However, should the internal mesh  408  need to be removed, the internal gasket  410  is conformable such that it can be removed from the opening  409  thereby allowing the internal mesh  408  to also be removed for servicing. The front body assembly  400  can also includes an outer mesh  416 . The outer mesh  416  can be secured to a top surface of the cap body  412 . 
     Although the internal mesh  408  and the outer mesh  416  are utilized, the acoustic channel provided through the opening  409  in the output portion  406  is not blocked by any of the components of the front body assembly  400  being inserted or coupled to the output portion  406 . In this regard, the internal gasket  410  is ring-shaped, and the cap body  412  is hollow or tubular. Further, the internal mesh  408  and the outer mesh  416  include numerous openings within the mesh structures that allow sound from the acoustic channel to properly emit from the front body assembly  400 . In other words, the internal mesh  408  and the outer mesh  416  are substantially acoustically neutral. 
     The parts of the front body assembly  400  can be formed of different materials (e.g., plastic, ceramic, metals, nylon, etc.). In one implementation, the front body  402  can be metal, the internal mesh  408  can be metal, the internal gasket  410  can be rubber, the cap body  412  can be metal, and the outer mesh  416  can be metal. As one example, the metal can be stainless steel. 
       FIG. 5  is a side view of a cap body  500  according to one embodiment of the invention. The cap body  500  includes a bottom portion  502  and a top portion  504 . In the bottom portion  502  includes threads  506 . The top portion  504  includes knurls  508 .  FIG. 6  is a cross-sectional view of a cap body  600  according to one embodiment of the invention. The cap body  600  includes a bottom portion  602  and a top portion  604 . The bottom portion  602  has external threads  606 . The top portion  604  includes knurls  608  about the periphery of the top portion  604 . In addition, the cap body  600  includes a recess region  610  for receiving a cover, such as a mesh cover. Additionally, the cap body  600  has an opening  612  that extends therethrough. The opening  612  couples to, extends to or is part of the acoustic channel for a front body (e.g., cap body  402 ) to which the cap body  600  is attached. The opening  612  internal to the cap body  600  can further include internal threads  614 . The internal threads  614  do not serve a mechanical purpose but have been shown to have beneficial acoustic impact on acoustical characteristics of the acoustic channel. 
       FIG. 7  is a cross-sectional view of an output portion  700  of a front body according to one embodiment of the invention. The output portion  700  includes a tapered structure  702  and an output structure  704 . A central portion of the output portion  700  extends an opening  706  which provides an acoustic channel through the output portion  700 . Internal to the output structure  704  are threads  708  for receiving compatible threads of a removable cap (e.g., cap body  412 ,  500 ,  600 ). Although the output portion  700  utilizes threads  708  to secure a removable cap to the output portion  700 , it should be recognized that in other embodiments different techniques can be utilized to secure a removable cap to the output portion  700 . 
       FIG. 8  is a cross-sectional view of a front body  800  according to one embodiment of the invention. As illustrated in  FIG. 8 , the front body  800  is fully assembled. Initially, it is noted that the front body  800  includes a base portion  802 . The base portion  802  serves to connect to a rear body of a headphone (e.g., rear body  104 ,  204 ). The front body  800  also includes an output portion  804 . The output portion  804  is, for example, constructed as is the output portion  700  illustrated in  FIG. 7 . Additionally, a removable cap  806  has been attached to the output portion  804 . In particular, the removable  806  has been screwed into the threaded opening in a top end of the output portion  804 . The removable cap  806  can have an outer mesh  808  secured to a top end of the removable cap  806 . The outer mesh  808  can be secured to the top end of the removable cap  806  by interference (frictional) fitting, adhesive, notches, protrusions, and the like. Additionally, an internal mesh  810  and a gasket  812  can be provided within the threaded opening of the output portion  804 . As illustrated in  FIG. 8 , the gasket  812  can be provided in the opening of the output portion  804  between the internal mesh  810  and a forward end of the removable cap  806  while inserted. When the removable cap  806  is screwed into the threaded opening of the output portion  804 , the gasket  812  can be compressed, which thereby serves to prevent the removable cap  806  from loosening. Hence, the gasket  812  can be considered as a retention device for the removable cap  806 . 
     According to another aspect, the invention can pertain to an ear tip for use with a headphone. The ear tip can include a deformable outer member and is suitable for in-ear operation. The deformable outer member enables the ear tip to readily conform to a user&#39;s ear. The ear tip can also include an inner member to structurally support the outer member and to facilitate attachment to a headphone. 
     The ear tip can, for example, be used with the headphones discussed above. For example, the ear tip can be removably attached to a headphone such as illustrated in  FIG. 1A . In one embodiment, the ear tips are soft and deformable. The ear tips can be used in-ear. Since the ear tips can readily deform, the ear tips can operate to substantially seal against a user&#39;s ear. For increased comfort, the ear tips can be provided in different sizes to accommodate variation in user ear sizes. The color and translucency of the ear tips can also vary. In addition, the materials used to form ear tips may vary. 
     An ear tip can be formed from an elastomer, which is a polymer with the property of elasticity. For example, the ear tip can be formed, in whole or in part, of silicone or silicone rubber. Generally, an ear tip may be formed from any suitable material which is capable of providing a seal with a surface of a human ear. An ear tip may be formed from materials including, but not limited to including, polyurethane (PU) foam, PU foam with a silicone skin, silicone gel with a silicone rubber skin, PU foam with a PU skin, silicone foam, or a thermoplastic (TPE) foam. In one embodiment, any relatively slow-rebounding material which may be deformed and then expand to conform to an original geometry may be used to form at least part of an ear tip. 
     Materials used to form an ear tip may also be treated to improve durability and/or cosmetic appearance. By way of example, PU foam may be chemically treated to reduce the number of visible surface pores and surface wrinkles. Alternatively, an outer later of material can be provided over the PU form to provide desired characterisitcs. In one embodiment, a silicone skin can be formed in a desired configuration for an ear tip and then an internally cavity can be filled with PU or PU foam. In another embodiment, a PU foam may have a silicone skin molded thereon, sprayed thereon, or otherwise applied thereon to provide a smooth cosmetic appearance. Hence, a cosmetic appearance may be created by treating a material from which an ear tip is formed, or a cosmetic appearance may be created by providing a layer, e.g., a layer of cosmetically appealing material, over the material from which an ear tip is formed. 
       FIGS. 9A-9E  are views of an ear tip  900  according to one embodiment of the invention.  FIG. 9A  is a front perspective view of the ear tip  900 ,  FIG. 9B  is a rear perspective view of the ear tip  900 , and  FIG. 9C  is a side perspective view of the ear tip  900 . 
     The ear tip  900  includes an outer structure  902  and an inner structure  904 . The ear tip  900  also has a top opening  906  provided at a front surface  908  of the ear tip  900 . The top opening  906  serves as an opening for audio sound (emitted from a headphone) to be directed into a user&#39;s ear canal. The ear tip  900  also has a bottom opening  910  at a rear surface  912 . At the rear surface  912 , a bottom edge  914  is provided around the bottom opening  910 . 
     The inner structure  904  is covered by the outer structure  902 . The outer structure  902  is adhered to or integral with the inner structure  904  at the front surface  908 . The outer structure  902  extends over and around the inner structure  902  but remains open at the bottom opening  910  at the rear surface  912 . Behind the front surface  908 , the outer structure  902  may be spaced apart from the inner structure  904 . 
     Alternatively, the outer structure  902  may be formed from a membrane component  902   a  and a solid component  902   b . The solid component  902   a  is arranged to be a slow-rebounding component that expands and conforms to a shape, e.g., a shape of an ear cavity in which the ear tip  900  is inserted, after being compressed. Outer structure  902  may be readily deformed, as for example by pressure applied using fingers. For example, in use, the ear tip  900  will be inserted into or adjacent a user&#39;s ear canal and the outer structure  902  can readily deform to substantially seal against a user&#39;s ear. In particular, the solid component  902   b  may deform to substantially seal against a user&#39;s ear. 
     In one embodiment, the outer structure  902  can include a cosmetic surface, which can be the exterior surface of the outer structure  902 . The cosmetic surface may be, in one embodiment, a silicone skin that is substantially bonded to an underlying material such as silicone gel, silicone foam, or PU foam. Hence, the outer structure  902  may include a first pliable material that may conform to the shape of an ear cavity, as well as a second pliable material that essentially forms a cosmetic surface. The second pliable material may cooperate with the first pliable material to conform to the shape of an ear cavity. In one embodiment, the outer structure  902  may effectively include two layers, namely a structural layer and a cosmetic layer. 
     Membrane component  902   a  may be deformed, and is formed from substantially the same material, or materials, used to form solid component  902   b . Membrane component  902   a  is arranged such that while outer structure  902  forms a substantially undercut sphere with a “filled” portion, where solid component  902   b  is effectively the filled portion, membrane component  902   a  forms an “unfilled” portion such that an air may effectively fill portions of outer structure  902 . 
       FIG. 9D  is a side view of the ear tip  900  according to one embodiment of the invention. The configuration of the outer structure  902  according to one embodiment of the invention is illustrated in  FIG. 9D . According to the embodiment illustrated in  FIG. 9D , the ear tip  900  can have a height (H) of 10.48 mm, the width (W 1 ) (diameter) of the front surface  908  can be 4.75 mm, the width (W 2 ) (diameter) of the rear surface  912  can be 10.01 mm. A fill height (F), which corresponds to a height of the solid component  902   b  of outer structure  902  is generally less than the height (H). The fill height (F) may extend slightly above the widest portion of ear tip  900 , as shown, although it should be appreciated that the fill height (F) may generally be any height that is less than the height (H). 
       FIG. 9E  is a cross-sectional view of the ear tip  900  according to one embodiment of the invention. The configuration of the inner structure  904  according to one embodiment of the invention is illustrated in  FIG. 9E . The inner structure  904  can be cylindrical, so as to have a tubular configuration. The top of the inner structure  904  adheres to or is integral with the top region of the outer structure  902  at the front surface  908 . Additionally, the internal configuration of the inner structure  904  can include one or more attachment features  916  that facilitates attachment of the inner structure  904  of the ear tip to a headphone. For example, the internal configuration of the inner structure  904  includes at least one recess that can serve as an attachment feature  916 . According to the embodiment illustrated in  FIG. 9E , the inner structure  904  can have a total height (h 1 ) of 6.66 mm, a distance d 1  from the front surface  908  to the start of the attachment feature  916  is 2.00 mm, the height (h 2 ) of the attachment feature  916  (recess) is 1.55 mm, the width (w 1 ) (diameter) of the top opening  906  is 2.40 mm, the width (w 2 ) at the attachment feature  916  is 3.99 mm, and the width (w 3 ) at the lower portion of the inner structure  904  is 3.61 mm. The fill height (F), as shown in  FIG. 9D , may be greater than or approximately equal to the total height (h 1 ). In one embodiment, the solid component  902   b  may be configured such that the fill height (F) that is approximately equal to the total height (h 1 ) where the solid component  902   b  substantially contacts the internal structure  904 , and have a larger fill height (F) at an interface with the membrane component  902   a.    
     In one embodiment, the hardness of the inner structure  904  and the outer structure  902  are configured differently. For example, the inner structure  904  can have a greater hardness that the outer structure  902 . In other words, in such an example, the outer structure  902  can be softer than the inner structure  904 . 
     Durometer is one of several ways to indicate the hardness of a material, defined as the material&#39;s resistance to permanent indentation. The term durometer is often used to refer to the measurement, as well as the instrument itself. Durometer is typically used as a measure of hardness in polymers, elastomers and rubbers. In one implementation, according to a durometer measurement, the durometer of the inner structure  904  can be sixty (60), and the durometer of the outer structure  902  can be forty (40). 
       FIGS. 10A-10E  are views of an ear tip  1000  according to one embodiment of the invention.  FIGS. 10A-10E  are views of an ear tip  1000  according to one embodiment of the invention.  FIG. 10A  is a front perspective view of the ear tip  1000 ,  FIG. 10B  is a rear perspective view of the ear tip  1000 , and  FIG. 100  is a side perspective view of the ear tip  1000 . The ear tip  1000  is smaller than the ear tip  900  illustrated in  FIGS. 9A-9E . 
     The ear tip  1000  includes an outer structure  1002  and an inner structure  1004 . The ear tip  1000  also has a top opening  1006  provided at a front surface  1008  of the ear tip  1000 . The top opening  1006  serves as an opening for audio sound (emitted from a headphone) to be directed into a user&#39;s ear canal. The ear tip  1000  also has a bottom opening  1010  at a rear surface  1012 . At the rear surface  1012 , a bottom edge  1014  is provided around the bottom opening  1010 . 
     The inner structure  1004  in contact with the outer structure  1002 . The outer structure  1002  is adhered to or integral with the inner structure  1004  at the front surface  1008 , and substantially along side surfaces of inner structure  1004 . The outer structure is arranged to be readily deformed. For example, in use, the ear tip  1000  will be inserted into or adjacent a user&#39;s ear canal and the outer structure  1002  can readily deform to substantially seal against a user&#39;s ear. 
       FIG. 10D  is a side view of the ear tip  1000  according to one embodiment of the invention. The configuration of the outer structure  1002  according to one embodiment of the invention is illustrated in  FIG. 10D . According to the embodiment illustrated in  FIG. 10D , the ear tip  1000  can have a height (H) of 9.58 mm, the width (W 1 ) (diameter) of the front surface  1008  can be 4.48 mm, the width (W 2 ) (diameter) of the rear surface  1012  can be 10.01 mm. 
       FIG. 10E  is a cross-sectional view of the ear tip  1000  according to one embodiment of the invention. The configuration of the inner structure  1004  according to one embodiment of the invention is illustrated in  FIG. 10E . The inner structure  1004  can be cylindrical, so as to have a tubular configuration. The top of the inner structure  1004  adheres to or is integral with the top region of the outer structure  1002  at the front surface  1008 . The sides of the inner structure  1004  also adhere to the outer structure  1002 . Additionally, the internal configuration of the inner structure  1004  can include one or more attachment features  1016  that facilitates attachment of the inner structure  1004  of the ear tip to a headphone. For example, the internal configuration of the inner structure  1004  includes at least one recess that can serve as an attachment feature  1016 . According to the embodiment illustrated in  FIG. 10E , the inner structure  1004  can have a total height (h 1 ) of 5.76 mm, a distance d 1  from the front surface  1008  to the start of the attachment feature  1016  is 1.10 mm, the height (h 2 ) of the attachment feature  1016  (recess) is 1.55 mm, the width (w 1 ) (diameter) of the top opening  1006  is 2.41 mm, the width (w 2 ) at the attachment feature  1016  is 3.99 mm, and the width (w 3 ) at the lower portion of the inner structure  1004  is 3.61 mm. 
     In one embodiment, the hardness of the inner structure  1004  and the outer structure  1002  are configured differently. For example, the inner structure  1004  can have a greater hardness that the outer structure  1002 . In other words, in such an example, the outer structure  1002  can be softer than the inner structure  1004 . The outer structure  1002  may be formed from a deformable material, such as a slow-rebounding material. In one implementation, according to a durometer measurement, the durometer of the inner structure  1004  can be about fifty (50), and the durometer of the outer structure  1002  can be about thirty (30). 
       FIGS. 11A-11E  are views of an ear tip  1100  according to one embodiment of the invention.  FIGS. 11A-11E  are views of an ear tip  1100  according to one embodiment of the invention.  FIG. 11A  is a front perspective view of the ear tip  1100 ,  FIG. 11B  is a rear perspective view of the ear tip  1100 , and  FIG. 11C  is a side perspective view of the ear tip  1100 . The ear tip  1100  is larger than the ear tip  900  illustrated in  FIGS. 9A-9E . 
     The ear tip  1100  includes an outer structure  1102  and an inner structure  1104 . The ear tip  1100  also has a top opening  1106  provided at a front surface  1108  of the ear tip  1100 . The top opening  1106  serves as an opening for audio sound (emitted from a headphone) to be directed into a user&#39;s ear canal. The ear tip  1100  also has a bottom opening  1110  at a rear surface  1112 . At the rear surface  1112 , a bottom edge  1114  is provided around the bottom opening  1110 . 
     The inner structure  1104  is in contact with the outer structure  1102 . The outer structure  1102  is adhered to or integral with the inner structure  1104  at the front surface  1108 , as well as along the sides of inner structure  1104 . The outer structure  1102  extends around the inner structure  1102  but remains substantially open at the bottom opening  1110  at the rear surface  1112 . In use, the ear tip  1100  will be inserted into or adjacent a user&#39;s ear canal and the outer structure  1102  can readily deform to substantially seal against a user&#39;s ear. 
       FIG. 11D  is a side view of the ear tip  1100  according to one embodiment of the invention. The configuration of the outer structure  1102  according to one embodiment of the invention is illustrated in  FIG. 11D . According to the embodiment illustrated in  FIG. 11D , the ear tip  1100  can have a height (H) of 11.53 mm, the width (W 1 ) (diameter) of the front surface  1108  can be 4.76 mm, the width (W 2 ) (diameter) of the rear surface  1112  can be 10.01 mm. 
       FIG. 11E  is a cross-sectional view of the ear tip  1100  according to one embodiment of the invention. The configuration of the inner structure  1104  according to one embodiment of the invention is illustrated in  FIG. 11E . The inner structure  1104  can be cylindrical, so as to have a tubular configuration. The top of the inner structure  1104  may adhere to or may be integral with the top region of the outer structure  1102  at the front surface  1108 . Additionally, the internal configuration of the inner structure  1104  can include one or more attachment features  1116  that facilitates attachment of the inner structure  1104  of the ear tip to a headphone. For example, the internal configuration of the inner structure  1104  includes at least one recess that can serve as an attachment feature  1116 . Sides of the inner structure  1104  may also be adhered to outer structure  1102 . According to the embodiment illustrated in  FIG. 11E , the inner structure  1104  can have a total height (h 1 ) of 7.71 mm, a distance d 1  from the front surface  1108  to the start of the attachment feature  1116  is 3.05 mm, the height (h 2 ) of the attachment feature  1116  (recess) is 1.55 mm, the width (w 1 ) (diameter) of the top opening  1106  is 2.40 mm, the width (w 2 ) at the attachment feature  1116  is 3.99 mm, and the width (w 3 ) at the lower portion of the inner structure  1104  is 3.61 mm. 
     In one embodiment, the hardness of the inner structure  1104  and the outer structure  1102  are configured differently. For example, the inner structure  1104  can have a greater hardness that the outer structure  1102 . In other words, in such an example, the outer structure  1102  can be softer than the inner structure  1104 . In one implementation, according to a durometer measurement, the durometer of the inner structure  1104  can be about sixty (60), and the durometer of the outer structure  1002  can be about forty (40). 
     Various materials used to form an ear tip may generally be processed to provide desirable aesthetic, or cosmetic, properties. For example, a PU foam with a relatively smooth exterior surface may be more pleasing to the eye than other PU foams. A relatively smooth exterior surface may be one with relatively few surface bubbles and/or relatively few wrinkles. To control the surface bubbles or, more generally, the pore size of the PU foam, the ratio of components of the PU foam may be changed. For example, the amount of silicon surfactants in the PU foam may be altered to substantially control the pore size associated with the PU foam. 
     In one embodiment, an inner structure of an ear tip may be formed from a solid PU, with PU foam overmolded onto the solid PU to form an outer structure. The PU foam may be treated to substantially minimize surface pores and wrinkles. 
     An ear tip may include an outer structure formed from a PU foam that is coated with a PU skin. Solid PU may be sprayed in a mold, for example, prior to filling the mold with PU foam, thereby resulting in a PU skin being formed on a PU structure. The PU skin may improve mechanical and chemical resistance, and also the cosmetic qualities of the ear tip. 
     A silicone skin or surface may be added to the surface of PU foam to improve the cosmetic qualities of an ear tip formed from the PU foam, as well as to enhance the durability of the PU foam. The silicone skin may be molded (e.g., over molded) onto the PU foam, or sprayed onto the PU foam. Alternatively, the PU form may be molded (e.g., over molded) onto the silicone skin. The silicone skin may also be applied by dipping the PU foam into silicone. A plasma or chemical process may be utilized to enable the silicone to effectively stick to the PU foam. A PU foam with a silicone skin generally has desirable chemical, mechanical, and environmental properties. 
     A relatively slow-rebounding ear tip may be formed from a silicone foam or gel that may be contained by a silicone rubber skin. Such a silicone rubber skin may be overmolded onto the silicone foam or gel. It should be appreciated that while the volume of PU foam can be pressed and then rebound, the volume of a silicone foam or gel may effectively be displaced. The silicone rubber skin may be provided for cosmetic purposes and/or for durability. In some instances, a silicone foam may also be used without a silicone rubber skin to form an ear tip. 
       FIG. 12  is a flow diagram of an ear tip formation process  1200  according to one embodiment of the invention. The ear tip formation process  1200  can, for example, be used to form ear tips utilized by headphones. The ear tips being formed can, for example, be the ear tips  900 ,  1000  or  1100  illustrated in  FIGS. 9A-11E . 
     The ear tip formation process  1200  can initially configure  1202  top and bottom molding plates. The molding plates are associated with a molding station (e.g., an injection molding station) of an assembly area. The molding plates can be custom formed for molding ear tips in accordance with the invention. The top and bottom molding plates can form a first mold. Next, an inner structure can be compression molded  1204  using a first moldable material injected into the first mold. As an example, the first mobile material can be silicone. Once molded, the formed inner structure can be cured  1206 . The inner structure can be cured  1206  using radiation, such as heat or UV light, and/or time. 
     Next, the molding station can be reconfigured  1208  by replacing one of the top and bottom molding plates. The new combination of molding plates can form a second mold. For example, the top molding plate utilized in the molding of the inner structure can be removed and replaced with a different top molding plate. In this case, the new top molding plate facilitates creation of an outer structure. The top and bottom molding plates may be sprayed or otherwise coated, in one embodiment, with a silicone or PU material to facilitate the creation of an exterior skin on an outer structure. After the molding station has been reconfigured  1208 , an outer structure can be compression molded  1210  using a second moldable material injected into the second mold. As an example, the second moldable material can also be silicone such as a silicone foam, or the second moldable material can be a PU foam or a TPE foam. In one embodiment, the deformability of the second moldable material is significantly greater than that of the first moldable material. When the outer structure is compression molded  1210  it is integrally formed onto an upper portion of the inner structure. Once molded, the formed outer structure can be cured  1212 . The combination of the inner structure and the outer structure results in an ear tip. Since the molding plate typically forms a plurality of structures at one time, the ear tip formation process  1200  can concurrently produce a plurality of ear tips. After the formed outer structure has been cured  1212 , the formed ear tip or tips can be removed  1214  from the molding plates. Following the block  1214 , the ear tip formation process  1200  can end. 
     In some instances, separate molding processes may be used to form an outer structure, as for example when the outer structure is formed from a first material and a second material overmolded onto the first material.  FIG. 13  is a flow diagram of an ear tip formation process  1300  which includes overmolding materials to form an outer structure of the ear tip according to another embodiment of the invention. The ear tip formation process  1300  can, for example, be used to form ear tips utilized by headphones. The ear tips being formed can, for example, be the ear tips  900 ,  1000 ,  1100  or  1500  illustrated in  FIGS. 9A-11E and 15 . However, the ear tips are not limited to being those illustrated in  FIGS. 9A-11E and 15 . 
     The ear tip formation process  1300  can initially configure  1302  top and bottom molding plates. The molding plates are associated with a molding station (e.g., an injection molding station) of an assembly area. The molding plates can be custom formed for molding ear tips in accordance with the invention. The top and bottom molding plates can form a first mold. Next, an inner structure can be compression molded  1304  using a first moldable material injected into the first mold. As an example, the first mobile material can be silicone. Once molded, the formed inner structure can be cured  1306 . The inner structure can be cured  1306  using radiation, such as heat or UV light, and/or time. 
     Next, the molding station can be reconfigured  1308  by replacing one of the top and bottom molding plates. The new combination of molding plates can form a second mold. For example, the top molding plate utilized in the molding of the inner structure can be removed and replaced with a different top molding plate. In this case, the new top molding plate facilitates creation of an outer structure. After the molding station has been reconfigured  1308 , a portion of an outer structure can be compression molded  1310  using a second moldable material injected into the second mold. As an example, the second moldable material can also be silicone such as a silicone foam, or the second moldable material can be a PU foam or a TPE foam. In one embodiment, the deformability of the second moldable material is significantly greater than that of the first moldable material. When the portion of the outer structure is compression molded  1310 , it is integrally formed onto an upper portion of the inner structure. Once molded, the formed portion of the outer structure can be cured  1311 . 
     The molding station can be reconfigured  1312  by replacing at least one of the top and bottom molding plates. The plate or plates may be reconfigured such that another portion of the outer structure may be compression molded. For example, a silicone skin may be formed over a silicone foam portion of the outer structure. Thus, a portion of the outer structure can be compression molded  1313 , e.g., overmolded, using a third moldable material injected into a third mold. Once molded, the outer structure can be cured  1314 . 
     The combination of the inner structure and the portions of the outer structure results in an ear tip. Since the molding plate typically forms a plurality of structures at one time, the ear tip formation process  1300  can concurrently produce a plurality of ear tips. After the formed outer structure has been cured  1314 , the formed ear tip or tips can be removed  1315  from the molding plates. Following the block  1315 , the ear tip formation process  1300  can end. 
     As previously mentioned, a coating such as a silicone skin may be applied to an outer structure of an ear tip through a dipping or spraying process.  FIG. 14  is a flow diagram of an ear tip formation process  1400  that includes applying a coating to an outer structure according to one embodiment of the invention. The ear tip formation process  1400  can, for example, be used to form ear tips utilized by headphones. The ear tips being formed can, for example, be the ear tips  900 ,  1000 ,  1100  or  1500  illustrated in  FIGS. 9A-11E and 15 . 
     The ear tip formation process  1400  can initially configure  1402  top and bottom molding plates. The molding plates are associated with a molding station (e.g., an injection molding station) of an assembly area. The molding plates can be custom formed for molding ear tips in accordance with the invention. The top and bottom molding plates can form a first mold. Next, an inner structure can be compression molded  1404  using a first moldable material injected into the first mold. As an example, the first mobile material can be silicone. Once molded, the formed inner structure can be cured  1406 . The inner structure can be cured  1406  using radiation, such as heat or UV light, and/or time. 
     Next, the molding station can be reconfigured  1408  by replacing one or both of the top and bottom molding plates. The new combination of molding plates can form a second mold. For example, the top molding plate utilized in the molding of the inner structure can be removed and replaced with a different top molding plate. In this case, the new top molding plate facilitates creation of an outer structure. After the molding station has been reconfigured  1408 , an outer structure can be compression molded  1410  using a second moldable material injected into the second mold. As an example, the second moldable material can also be silicone such as a silicone foam, or the second moldable material can be a PU foam or a TPE foam. In one embodiment, the deformability of the second moldable material is significantly greater than that of the first moldable material. When the outer structure is compression molded  1410  it is integrally formed onto an upper portion of the inner structure. 
     Once molded, the formed outer structure can be cured  1411 . The combination of the inner structure and the outer structure results in an ear tip. Since the molding plate typically forms a plurality of structures at one time, the ear tip formation process  1400  can concurrently produce a plurality of ear tips. After the formed outer structure has been cured  1412 , the formed ear tip or tips can be removed  1415  from the molding plates. An outer coating can be applied  1416  to ear tips. That is, a cosmetic surface can be applied to ear tips. Applying an outer coating may include, but is not limited to including, spraying an outer coating material onto the outer structure or dipping the outer structure into an outer coating material. By way of example, a silicone coating may be applied to a PU foam. Following the block  1416 , the ear tip formation process  1400  can end. 
     As previously mentioned, an outer structure of an ear tip may be formed from a material that is at least partially covered (e.g., coated) with another material. With reference to  FIG. 15 , an ear tip with an outer structure that is formed from a material, e.g., PU foam, that is covered (e.g., coated) by another material, e.g., a silicone film, is shown in accordance with an embodiment of the invention. An ear tip  1500  includes an inner structure  1504  that is covered by an outer structure  1502 . The outer structure  1502  is adhered to or integral with the inner structure  1504  at a front surface  1508 , as well as along sides of inner structure  1504 . The outer structure  1502  extends over and around the inner structure  1504  but remains open at a bottom opening  1510  at a rear surface  1512 . 
     The outer structure  1502  includes a first material  1502   a  and a second material  1502   b . The first material  1502   a  may be, in one embodiment, a PU foam while the second material  1502   b  may be silicone. The second material  1502   b  may form a cosmetic surface of outer structure  1502 . In general, the second material  1502   b  may form at least an exterior surface of the outer structure  1502 . 
     In the ear tip formation processing  1200  the inner structure can be formed before the outer structure. However, in alternative embodiment, the outer structure can be formed before the inner structure. This alternative approach can yield improved durability and/or cosmetic appearance. 
       FIG. 16  is a flow diagram of an ear tip formation process  1600  according to one embodiment of the invention. The ear tip formation process  1600  can, for example, be used to form ear tips utilized by headphones. The ear tips being formed can, for example, be the ear tips  900 ,  1000 ,  1100  or  1500  illustrated in  FIGS. 9A-11E and 15 . 
     The ear tip formation process  1600  can initially configure  1602  top and bottom molding plates. The molding plates are associated with a molding station (e.g., an injection molding station) of an assembly area. The molding plates can be custom formed for molding ear tips in accordance with the invention. The top and bottom molding plates can form a first mold. Next, an outer structure can be compression molded  1604  using a first moldable material injected into the first mold. As an example, the first mobile material can be silicone. Once molded, the formed outer structure can be cured  1606 . The outer structure can be cured  1606  using radiation, such as heat or UV light, and/or time. 
     Next, the molding station can be reconfigured  1608  by replacing one of the top and bottom molding plates. The new combination of molding plates can form a second mold. For example, the top molding plate utilized in the molding of the outer structure can be removed and replaced with a different top molding plate. In this case, the new top molding plate facilitates creation of an inner structure. The formed outer structure forms an inner cavity into which the inner structure is to be formed. The exposed inner surface of the formed outer structure may be sprayed or otherwise coated, in one embodiment, with a primer to assist with adhesion to the inner surface of the inner cavity of the outer structure. For example, if the first moldable material is silicone, which has low surface energy, a primer coating can assist with adhesion to other materials. On example of a suitable primer may be Silane. Silane is a chemical compound with chemical formula SiH 4 . 
     After the molding station has been reconfigured  1608  and any primer applied, an inner structure can be compression molded  1610  using a second moldable material injected into the second mold. As an example, the second moldable material can also be silicone such as silicone foam, or the second moldable material can be a PU foam or a TPE foam. In one embodiment, the deformability of the first moldable material is significantly greater than that of the second moldable material. When the inner structure is compression molded  1610  it is integrally formed within the inner cavity of the outer surface. Once molded, the formed outer structure can be cured  1612 . The combination of the inner structure and the outer structure results in an ear tip. Since the molding plate typically forms a plurality of structures at one time, the ear tip formation process  1600  can concurrently produce a plurality of ear tips. After the formed inner structure has been cured  1612 , the formed ear tip or tips can be removed  1614  from the molding plates. Following the block  1614 , the ear tip formation process  1600  can end. 
     In another embodiment, instead of applying a primer to the inner surface of the outer structure, corona processing can by induced on the inner surface of the outer structure so that adhesion characteristics can be improved. The corona processing acts as an electrically induced surface treatment. In generally, a corona discharge is an electrical discharge brought on by the ionization of a fluid surrounding a conductor, which occurs when the potential gradient (the strength of the electric field) exceeds a certain value, but conditions are insufficient to cause complete electrical breakdown or arcing. 
     In one embodiment of the ear tip formation process  1600 , the formed outer structure can be highly durable and elastic such that it can be inverted. The application of the primer can be performed in mold or out of mold. In one embodiment, if may be advantageous to invert the inner surface of the formed outer structure so that it can be coated or sprayed with the primer or altered by corona processing. Thereafter, the outer structure can be uninverted. 
     In another embodiment, an inner structure for an ear tip can substantially extend through the height of the ear tip. The extended inner structure can improve tear strength for an open end of the ear tip. The extended inner structure can also reduce likelihood of delamination between the material of the inner structure and the material for the outer structure. As noted above, the material used for the inner structure and the outer structure can vary depending on implementation. In one example, the material for the inner structure is a solid PU, and the material for the outer material is PU foam. In another example, the material for the inner structure is silicone, and the material for the outer structure is PU foam. The material for the outer structure can be over-molded onto the material for the inner structure, or the material for the inner material can be over-molded onto the material for the outer material. 
       FIG. 17  illustrates an ear tip  1700  with an extended inner structure according to one embodiment of the invention. The ear tip  1700  has an outer structure  1702 . The outer structure  1702  is adhered to or integral with the inner structure  1704  at a front surface  1708 , as well as along sides of inner structure  1704 . The outer structure  1702  extends over and around the inner structure  1704  but remains open at a bottom opening  1710  at a rear surface  1712 . 
     The inner structure  1704  has a lower portion  1704   a  and an upper portion  1704   b . The lower portion  1704   a  of the inner structure  1704  is provided at a lower portion of the ear tip  1700 , while the upper portion  1704   b  of the inner structure  1704  is provided at an upper portion of the ear tip  1700 . As compared to other embodiments where the inner structure includes only the lower portion  1704   a  adjacent the lower portion of the ear tip  1700 , in this embodiment the inner structure  1704  extends through the ear tip  1700 . The addition of the upper portion  1704   b  can provide the ear tip  1700  with greater durability (e.g., increased tear strength). 
     The outer structure  1702  includes a first material  1702   a . The first material  702   a  may be, in one embodiment, a PU foam. Optionally, such as illustrated in  FIG. 15 , the outer structure  1702  can also include a second material (e.g., second material  1502   b ). The second material for the outer structure  1702  may, for example, be silicone. The second material for the outer structure  1702 , if provided, may form a cosmetic surface of outer structure  1702 . In general, although not illustrated in  FIG. 17 , the second material for the outer structure  1702  may form at least an exterior surface of the outer structure  1702 . The ear tip  1700  can be formed with a molding process that forms the inner structure  1704  before the outer structure  1702 , or the ear tip  1700  can be formed with a molding process that forms the inner structure  1704  after the outer structure  1702 . 
       FIG. 18  is a cross-sectional view of an ear tip  1800  with an extended inner structure  1802  according to one embodiment of the invention. The ear tip  1800  can be formed from an inner member  1802  and an outer member  1804 . In this exemplary embodiment, the inner member  1802  can be a solid urethane elastomer (e.g. solid PU) that extends substantially entirely through the ear tip  1800 , which can serve to improve tear strength. The outer member  1804  can be an urethane foam (e.g., PU foam). 
       FIG. 19A  is a rear view,  FIG. 19B  is a side view, and  FIG. 19C  is a cross-sectional view of an ear tip  1900  according to one embodiment. The ear tip  1900 , like the ear tip  1700  illustrated in  FIG. 17 , has an extended inner structure. 
     The ear tip  1900  has an outer structure  1902  and an inner structure  1904 . The configuration (e.g., shape) of the outer structure  1902  according to one embodiment is illustrated in  FIG. 19B , which can be referred as a spherical. Here, the sides of the outer structure  1902  are rounded or curved. According to the embodiment illustrated in  FIG. 19B , the ear tip  1900  can have a height (H) of 11.53 mm, the width (W 1 ) (diameter) of the front surface  1108  can be 4.76 mm, the width (W 2 ) (diameter) of the rear surface  1914  can be 10.01 mm. However, it should be understood that these sizes are exemplary and that the sizes vary with implementation. Often, the ear tips  1900  are formed in various sizes (e.g., small, medium and large) to accommodate user&#39;s with different size ears. 
     In  FIG. 19C , the configuration of the inner structure  1904  according to one embodiment is illustrated. The inner structure  1904  can be formed with a first compression molding process, and the outer structure  1902  can be formed with a second compression molding process. The inner structure  1904  can be cylindrical, so as to have a tubular configuration. The front region of the inner structure  1904  provides an opening  1906  through which audio sound can be provided to a user&#39;s ear. The front region of the inner structure  1904  may adhere to or may be integral with the front region of the outer structure  1902  at a front surface  1908 . Additionally, the internal configuration of the inner structure  1904  can include one or more attachment features that facilitate attachment of the inner structure  1904  of the ear tip  1900  to a headphone. For example, the internal configuration of the inner structure  1904  can include at least one recess  1909  that can serve as an attachment feature. Outer sides of the inner structure  1904  may also be adhered to outer structure  1902 . In one embodiment, the hardness of the inner structure  1904  and the outer structure  1902  are configured differently. For example, the inner structure  1904  can have a greater hardness that the outer structure  1902 . In other words, in such an example, the outer structure  1902  can be softer than the inner structure  1904 . In one implementation, according to a durometer measurement, the durometer of the inner structure  1904  can be about sixty (60), and the durometer of the outer structure  1902  can be about forty (40). The ear tip  1900  also has a rear region  1910 . The rear region  1910  can provide an opening  1912  for receiving an ear tip. The rear portion of the inner structure  1904  may adhere to or may be integral with the rear region of the outer structure  1902  at the rear region  1910  of the ear tip  1900 . More generally, in one embodiment, some or all of the outer sides of the inner structure  1904  can adhere to or be integral with some or all of the inner sides of the outer structure  1902 . 
       FIGS. 20A and 20B  illustrated a flow diagram of an ear tip formation process  2000  according to one embodiment. The ear tip formation process  2000  can, for example, be used to form ear tips utilized by headphones. The ear tips being formed can, for example, be the ear tips  1800  or  1900  illustrated in  FIGS. 18-19C . 
     The ear tip formation process  2000  can initially form  2002  an inner structure for an ear tip being formed. The inner ear structure for the ear tip can be formed in a variety of different ways, including by a molding process. 
     After obtaining the inner structure, the ear tip formation process  2000  can form an outer structure for the ear tip. The outer structure can be formed using molding plates associated with a molding station (e.g., an injection molding station) at an assembly area. The molding plates can be custom formed for molding ear tips in accordance with the invention. To form the outer structure for the ear tip, a top mold having at least one protrusion and a bottom mold having at least one ear tip cavity can be provided  2004 . A sheet of a first material can be placed  2006  over the ear tip cavity in the bottom mold. The sheet can be a thin sheet of polyurethane (e.g., thermoset polyurethane (TPU). For example, the sheet can be a polyurethane sheet (or film) with a thickness of 0.1 mm. More generally, the sheet has a thickness of 0.5-5 mm and can be formed of an elastomer. 
     Next, a quantity of a second material can be deposited  2008  on the sheet and adjacent the ear tip cavity in the bottom mold. The second material is used in forming the outer structure for the ear tip. For example, the second material can be a polyurethane form. Next, the sheet and the second material deposited there on can be drawn  2010  into the cavity. For example, in one implementation, a vacuum can be induced to draw  2010  the sheet as well as at least a portion of the deposited second material into the cavity. In one implementation, the bottom mold it is a porous metal mold (e.g., porous aluminum or steel), such that when a vacuum is imposed, a pressure difference can be formed to draw the sheet and the at least a portion of the deposited second material into the cavity. 
     Thereafter, the inner structure that was previously formed  2002  can be placed  2012  onto the protrusion of the top mold. The protrusion of the top mold can be designed to receive the inner structure for the ear tip being formed. The top mold and the bottom mold can then be coupled  2014  together with the protrusion being inserted into the cavity. At this point, the second material can be cured  2016 . The curing can be facilitated through heat, such as through heating of one or more of the molds. 
     After the second material has been cured  2016 , the top mold can be removed  2018 . Any excess material, namely, the second material, can also be removed  2020 . At this point, the ear tip has been formed and can then be removed  2022  from the bottom mold. In one implementation, air pressure can be applied to the porous bottom mold to cause the formed ear tip to dislodge from the bottom mold. Following the block  2022 , the ear tip formation process  2000  can end. 
       FIGS. 21A-21G  are cross-sectional diagrams illustrating ear tip formation according to one embodiment of the invention. 
       FIG. 21A  illustrates a bottom mold  2100  according to a first stage of the ear tip formation. The bottom mold  2100  includes a cavity  2102 . The cavity  2102  is configured to have a shape suitable for formation of an outer member of the ear tip. In one embodiment, the bottom mold  2100  can also include a plurality of holes  2104 . In other words, the bottom mold can be referred to as a porous mold, and/or the cavity  2102  can be referred to as a porous cavity. In addition, an elastomer film  2106  (e.g., polyurethane) is provided for formation of the ear tip. The elastomer film  2106  can provide an outer surface for the ear tip being formed. 
       FIG. 21B  illustrates the bottom mold  2100  according to a second stage of the ear tip formation. In the second stage, the elastomer film  2106  is placed over the cavity  2102 . In doing so, the elastomer film  2106  extends beyond simply covering the cavity  2102 . Additionally, a quantity of viscous outer material  2108  (e.g., polyurethane foam) can be deposited on the elastomer film  2106  over the cavity  2102 . 
     Then, a vacuum pressure can be applied to the bottom mold  2100  (or at least the cavity  2102  portion thereof). The vacuum pressure can be applied to the cavity  2102  since the bottom mold  2100  (or the cavity  2102 ) is porous. As a result, the viscous outer material  2108  is drawn into the cavity  2102 . 
       FIG. 21C  illustrates the bottom mold  2100  according to a third stage of the ear tip formation. Here, the elastomer film  2106  and the viscous outer material  2108  previously over the cavity  2102  are now within the cavity  2102 . Through application of heat, the viscous outer material  2108  can expand to fill the cavity  2102 . 
       FIG. 21D  illustrates a top mold  2110  and the bottom mold  2100  according to a fourth stage of the ear tip formation. The top mold  2110  can include a protrusion  2112  configured to receive an inner member  2114  (e.g., inner core element for the ear tip). Typically, the inner member  2114  is separately molded and thus available to be provided on the protrusion  2112 . In one implementation, the top mold  2110  can be formed of steel. 
       FIG. 2E  illustrates formation of the ear tip according to a fifth stage of the ear tip formation. To form the ear tip, the inner member  2114  is then shaped and connected to the inner member  2114  by bring the top mold  2110  and the bottom mold  2100  together. As shown in  FIG. 2E , when the top mold  2110  and the bottom mold  2100  are brought together, the protrusion  2112  of the top mold  2110 , having the inner member  2114  provided thereon, is inserted within the cavity  2102 . Consequently, an outer member  2116  for the ear tip is formed. The outer surface of the outer member  2116  is provided by the viscous outer material  2108  conformed against the inner surface of the cavity  2102  via the elastomer film  2106 . In doing so, the outer member  2116  is attached to the inner member  2114 . For example, the outer member  2116  can be molded onto a portion of the inner member  2114 . The viscous outer material  2108  can be then cure or solidify. The top mold  2110  can be separated from the bottom mold  2100 . 
     When the top mold  2110  and the bottom mold  2100  are brought together, some of the viscous outer material  2108  that was drawn into the cavity  2102  can be displaced from the cavity  2102 . In other words, a portion of the viscous outer material  2108  can overflow outward from the cavity  2102 . The overflowed outer material  2108 ′ can reside on the top of the bottom mold  2100 . 
       FIG. 21F  illustrates formation of the ear tip according to a sixth stage of the ear tip formation. The sixth stage provides for removal of undesired materials from the ear tip after removing the top mold  2110 . A heated die  2118  can be used to separate the residual or undesired materials from the ear tip that has been formed. For example, the residual or undesired materials can include any excess portion of the elastomer film  2106  as well as any of the viscous outer material  2108 ′ that displaces from the cavity  2102  to the surface of the bottom mold  2100 . The heated die  2118  can be brought against the top surface of the bottom mold  2100  adjacent the cavity  2102 . The heated die  2118  serves to separate the formed ear tip from any residual or undesired portions of (i) that portion of the viscous outer material  2108 ′ that has overflowed onto the top of the bottom surface  2100 , and/or (ii) that excess portion of the elastomer film  2106  that remains on the top of the bottom surface  2100 . 
       FIG. 21G  illustrates formation of the ear tip according to a seventh stage of the ear tip formation in which the ear tip is fully formed. Thereafter, the formed ear tip can be removed from the bottom mold  2100 . In one embodiment, to easily remove the formed ear tip from the bottom mold  2100 , air pressure can be used to push the formed ear tip out of the cavity  2102 . Since the bottom portion  2100  or at least its cavity  2102  has holes, an applied air pressure can be supplied to the cavity  2102  to withdraw of the formed ear tip from the cavity  2102 , and usually without any damage thereto. 
     Although the ear tip formation illustrated in  FIGS. 21A-21G  depict formation of a single ear tip, it should be understood that a plurality of ear tips can be concurrently formed, such as in a batch. In such case the elastomer film  2106  can be provide as a sheet of elastomer material that extends over the cavities used to form the plurality of ear tips concurrently. 
     The ear tips being formed can, for example, be formed from one or more elastomers. An ear tip may be formed from materials including, but not limited to including, polyurethane (PU) foam, PU foam with a silicone skin, silicone gel with a silicone rubber skin, PU foam with a PU skin, silicone foam, or a thermoplastic (TPE) foam. In the case of embodiments with an inner structure and an outer structure, the inner structure can be less compliant, so as to provide more structural support, while the outer structure can be more compliant, so as to adapt to a user&#39;s ear and provide a comfortable fit. Although the inner structure and the outer structure can be formed of the same material or materials of a like composition, which can facilitate bonding between the inner structure and the outer structure, it is not necessary that the materials used for the inner structure and the outer structure be the same. 
     In one embodiment, the outer structure can be formed with a gel or foam, such as silicone gel, silicone foam or polyurethane foam. For durability and/or cosmetics reasons, exposed portions of the outer structure can be covered. For example, the formed gel or foam of the outer structure that is exposed can be covered (e.g., by a film or by spray) with silicone, polyurethane or some other material. As another example, a layer of silicon can be molded onto the exposed portion of the formed gel or foam of the outer structure. 
     In another embodiment an ear tip can include a filter for substantially blocking foreign matter. An inner structure of an ear tip may include a filter such as a mesh. The filter can, for example, be formed of metal, such as stainless steel, or a polymer, such as nylon. 
     The various aspects, features, embodiments or implementations of the invention described above can be used alone or in various combinations. 
     This application references: (i) U.S. patent application Ser. No. 12/124,471, filed May 21, 2008, entitled “INVERTIBLE EAR TIPS FOR AN EAR PIECE”, which is hereby incorporated herein by reference; (ii) U.S. patent application Ser. No. 12/205,749, filed Sep. 5, 2008, entitled “EARPHONE WITH REMOVABLE COMPONENT”, which is hereby incorporated herein by reference; and (iii) U.S. patent application Ser. No. 12/205,748, filed Sep. 5, 2008, entitled “REMOVABLE EAR TIP FOR EARPHONE”, which is hereby incorporated herein by reference. 
     The many features and advantages of the present invention are apparent from the written description. Further, since numerous modifications and changes will readily occur to those skilled in the art, the invention should not be limited to the exact construction and operation as illustrated and described. Hence, all suitable modifications and equivalents may be resorted to as falling within the scope of the invention.

Metadata:
Filing Date: 20170213
Publication Date: 20190319
Grant Date: 20190319
Priority Date: 20071019
Inventors: SIAHAAN, EDWARD
STIEHL, KURT R.
TISCARENO, VICTOR M.
LIN, WEY-JIUN
Frazier, Cameron P.
PREST, CHRISTOPHER D.
HAYASHIDA, JEFFREY Y.
Assignee: APPLE INC
CPC Classifications: [{"code": "B29C43/021", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R1/1058", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C43/183", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C2043/5808", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C2043/3605", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29L2031/753", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29K2021/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/1016", "inventive": true, "first": true, "tree": "[]"}, {"code": "B29K2083/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/1016", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C43/021", "inventive": true, "first": true, "tree": "[]"}, {"code": "B29C2043/3605", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C2043/5808", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C43/183", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29K2021/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29K2083/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C43/021", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29L2031/753", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/1058", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R1/1016", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04R1/1058", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C2043/3605", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C43/183", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C2043/5808", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29K2083/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29L2031/753", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29K2021/00", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 42784294