PATENT DOCUMENT

Publication Number: US-8265323-B2
Application Number: US-20574908-A
Country: US
Kind Code: B2

Title: Earphone with removable component

Abstract:
An earphone or a removable component for use with an earphone are disclosed. As an example, the removable component can be a cap, filter or cover. According to one aspect, a headphone can provide improved approaches to substantially prevent foreign matter from hindering performance. However, when foreign matter has nevertheless accumulated, a user of the headphone can themselves clean the accumulated foreign matter without any tools or professional assistance. In one embodiment, a cover or filter is position and removably secured proximate to an entry to an acoustic channel of the headphone so that the foreign matter can be substantially blocked from ever entering the acoustic channel. In one embodiment, the cover or filter can be provided as part of a removable structure, e.g., cap, so that the cover or filter can be cleaned, replaced or otherwise serviced.

Claims:
1. An earphone, comprising:
 an earphone housing having an acoustic channel opening to an acoustic channel; 
 a removable cap having a threaded portion extending outwardly therefrom, the treaded portion having a plurality of threads on an external surface of the threaded portion, the threaded portion being configured to attach said removable cap to said earphone housing proximate to the acoustic channel opening, said removable cap having an outer mesh cover, wherein the outer mesh cover covers the acoustic channel opening while said removable cap is attached to said earphone housing; and 
 an ear piece configured to removably attach over at least a portion of said removable cap, said ear piece including at least (i) an inner structure that provides structural support for said ear piece, said inner structure being configured to removably attach to at least one of said removable cap and said earphone housing, and said inner structure having a top end and a bottom end; and (ii) an outer structure integrally formed about said top end of said inner structure, said outer structure being deformable so as to deform during in-ear usage, 
 wherein said inner structure is formed from an elastomer of a first hardness and said outer structure is formed from an elastomer of a second hardness, and wherein the second hardness is less than the first hardness. 
 
     
     
       2. An earphone as recited in  claim 1 , wherein the outer mesh cover is provided proximate to an outer end of the acoustic channel. 
     
     
       3. An earphone as recited in  claim 2 , wherein the outer mesh serves to substantially block debris from entering the acoustic channel. 
     
     
       4. An earphone as recited in  claim 2 , wherein said removable cap can be removed by a user to clean debris from the outer mesh. 
     
     
       5. An earphone as recited in  claim 2 , wherein no tools are required for a user to remove said removable cap to clean debris from the outer mesh. 
     
     
       6. An earphone as recited in  claim 2 , wherein said earphone further comprises:
 an internal mesh across the acoustic channel opening within said earphone housing. 
 
     
     
       7. An earphone as recited in  claim 1 , wherein said earphone further comprises:
 a gasket disposed at an interface between said removable cap and said earphone housing. 
 
     
     
       8. An earphone as recited in  claim 1 , wherein said removable cap includes knurls to facilitate removal of said removable cap from said earphone housing. 
     
     
       9. An earphone as recited in  claim 1 , wherein the acoustic channel opening includes internal threads, and wherein the plurality of threads on the external surface of the threaded portion of said removable cap include external threads, and wherein the internal threads and the external threads cooperate to attach said removable cap to said earphone housing. 
     
     
       10. An earphone as recited in  claim 9 , wherein said earphone further comprises:
 a gasket disposed at an interface between said removable cap and said earphone housing, 
 wherein when said removable cap is attached to said earphone housing using the internal threads and the external threads, said gasket is compressed to provide a retention force to further secure said removable cap to said earphone housing. 
 
     
     
       11. An earphone as recited in  claim 1 ,
 wherein the outer mesh cover is provided at an outer end of the acoustic channel, and 
 wherein said earphone further comprises:
 an internal mesh provided within the acoustic channel opening of said earphone housing. 
 
 
     
     
       12. An earphone as recited in  claim 1 , wherein said removable cap and said earphone housing are metal. 
     
     
       13. An earphone as recited in  claim 12 , wherein the outer mesh cover is metal. 
     
     
       14. An earphone as recited in  claim 12 , wherein the metal is stainless steel. 
     
     
       15. An earphone as recited in  claim 1 , wherein said earphone is an in-ear earphone. 
     
     
       16. A headphone, comprising:
 a headphone body having an acoustic channel and an acoustic channel opening to the acoustic channel; 
 a removable cap having a cover, said removable cap being configured to attach to said headphone body adjacent and/or within the acoustic channel opening so that the cover serves to substantially block unwanted debris from entering the acoustic channel while said removable cap is attached to said headphone body; 
 a mesh provided within the acoustic channel of said earphone housing; and 
 an ear piece configured to removably attach over at least a portion of said removable cap, said ear piece including at least (i) an inner structure that provides structural support for said ear piece, said inner structure being configured to removably attach to at least one of said removable cap and said headphone body, and said inner structure having a top end and a bottom end; and (ii) an outer structure integrally formed about said top end of said inner structure, said outer structure being deformable so as to deform during in-ear usage, 
 wherein said inner structure is formed from an elastomer of a first hardness and said outer structure is formed from an elastomer of a second hardness, and wherein the second hardness is less than the first hardness. 
 
     
     
       17. A headphone as recited in  claim 16 , wherein the cover is a mesh cover. 
     
     
       18. A headphone as recited in  claim 17 , wherein no tools are required for a user to remove said removable cap to clean debris from the cover. 
     
     
       19. A headphone as recited in  claim 16 , wherein said earphone further comprises:
 a gasket disposed at an interface between said removable cap and said headphone body. 
 
     
     
       20. A headphone as recited in  claim 16 , wherein said headphone is an in-ear headphone. 
     
     
       21. A headphone, comprising:
 a headphone body having an acoustic channel and an acoustic channel opening to the acoustic channel; 
 a removable insert configured to attach to said headphone body proximate to the acoustic channel opening so as to substantially block unwanted debris from entering the acoustic channel while said removable insert is attached to said headphone body, wherein sound can emit from the acoustic channel, even while said removable insert is attached, without substantial interference due to said removable insert, and wherein the removable insert includes knurls to facilitate removal of said removable insert from said headphone body; and 
 an ear piece configured to removably attach over at least a portion of said removable insert, said ear piece including at least (i) an inner structure that provides structural support for said ear piece, said inner structure being configured to attach to the headphone, and said inner structure having a top end and a bottom end; and (ii) an outer structure integrally formed about said top end of said inner structure, said outer structure being deformable so as to deform during in-ear usage, 
 wherein said inner structure is formed from an elastomer of a first hardness and said outer structure is formed from an elastomer of a second hardness, wherein the second hardness is less than the first hardness.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional Patent Application No. 60/999,660, filed Oct. 19, 2007, entitled “INVERTIBLE EAR TIPS FOR AN EARBUD”, which is herein incorporated herein by reference. 
     This application also 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; and (ii) 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. 
    
    
     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. Furthermore, in-ear headsets or headphones can suffer from performance degradation due to debris (such as ear wax) accumulating on or in the in-ear headsets or headphones. 
     SUMMARY OF THE INVENTION 
     The invention pertains to an earphone or a removable component for use with an earphone. As an example, the removable component can be a cap, filter or cover. As another example, the removable component can be an ear tip. 
     According to one aspect, the invention can pertain to a headphone that substantially prevents foreign matter from hindering performance. However, when foreign matter has nevertheless accumulated, a user of the headphone can themselves clean the accumulated foreign matter without any tools or professional assistance. In one embodiment, a cover or filter is positioned and removably secured proximate to an entry to an acoustic channel of the headphone so that the foreign matter can be substantially blocked from ever entering the acoustic channel. In one embodiment, the cover or filter can be provided as part of a removable structure, e.g., cap, so that the cover or filter can be cleaned, replaced or otherwise serviced. 
     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 earphone, one embodiment of the invention can, for example, include at least: an earphone housing having an acoustic channel opening to an acoustic channel; and a removable cap configured to attach to the earphone housing proximate to the acoustic channel opening. The removable cap can have an outer mesh cover. The outer mesh cover can cover the acoustic channel opening while the removable cap is attached to the earphone housing. 
     As a headphone, one embodiment of the invention can, for example, include at least: a headphone body having an acoustic channel and an acoustic channel opening to the acoustic channel; and a removable cap having a cover, the removable cap being configured to attach to the headphone body adjacent and/or within the acoustic channel opening so that the cover serves to substantially block unwanted debris from entering the acoustic channel while the removable cap is attached to the headphone body. 
     As a headphone, another embodiment of the invention can, for example, include at least: a headphone body having an acoustic channel and an acoustic channel opening to the acoustic channel; and a removable insert configured to attach to the headphone body proximate to the acoustic channel opening so as to substantially block unwanted debris from entering the acoustic channel while the removable insert is attached to the headphone body. During operation, sound can emit from the acoustic channel, even while the removable insert is attached, without substantial interference due to the removable insert. 
     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 cross-sectional view of the ear tip according to another embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The invention pertains to an earphone or a removable component for use with an earphone. As an example, the removable component can be a cap, filter or cover. As another example, the removable component can be an ear tip. 
     According to one aspect, the invention can pertain to a headphone that substantially prevents foreign matter from hindering performance. However, when foreign matter has nevertheless accumulated, a user of the headphone can themselves clean the accumulated foreign matter without any tools or professional assistance. In one embodiment, a cover or filter is positioned and removably secured proximate to an entry to an acoustic channel of the headphone so that the foreign matter can be substantially blocked from ever entering the acoustic channel. In one embodiment, the cover or filter can be provided as part of a removable structure, e.g., cap, so that the cover or filter can be cleaned, replaced or otherwise serviced. 
     Exemplary embodiments of aspects of the present 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, embodiment 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 . In 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 services (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 . At 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  300  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 match  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 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 camp 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 one embodiment, the 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. 
       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 phone  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  is spaced apart from the inner structure  904 . The separation between the outer structure  902  and the inner structure  904  can be filled with air. Hence, the separation with air can be referred to as an air interface. The separation between the outer structure  902  and the inner structure  904  allows the outer structure to be readily deformed. 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. 
       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.  9 D, 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. 
       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. 
     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. 10C  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 phone  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  is covered by the outer structure  1002 . The outer structure  1002  is adhered to or integral with the inner structure  1004  at the front surface  1008 . The outer structure  1002  extends over and around the inner structure  1002  but remains open at the bottom opening  1010  at the rear surface  1012 . Behind the front surface  1008 , the outer structure  1002  is spaced apart from the inner structure  1004 . The separation between the outer structure  1002  and the inner structure  1004  can be filled with air. Hence, the separation with air can be referred to as an air interface. The separation between the outer structure  1002  and the inner structure  1004  allows the outer structure 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 . 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 . In one implementation, according to a durometer measurement, the durometer of the inner structure  1004  can be fifty (50), and the durometer of the outer structure  1002  can be 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 phone  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 covered by the outer structure  1102 . The outer structure  1102  is adhered to or integral with the inner structure  1104  at the front surface  1108 . The outer structure  1102  extends over and around the inner structure  1102  but remains open at the bottom opening  1110  at the rear surface  1112 . Behind the front surface  1108 , the outer structure  1102  is spaced apart from the inner structure  1104 . The separation between the outer structure  1102  and the inner structure  1104  can be filled with air. Hence, the separation with air can be referred to as an air interface. The separation between the outer structure  1102  and the inner structure  1104  allows the outer structure to be readily deformed. For example, 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  adheres to or is 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 . 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 sixty (60), and the durometer of the outer structure  1002  can be forty (40). 
       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 con figure 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 are 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 is reconfigured  1280  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. Hence, after the molding station has been reconfigured  1208 , and 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. However, 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 structure at one time, the ear tip formation process  1200  can concurrently produce a plurality of ear tips. After the formed outer structure have been cured  1212 , the formed ear tips can be removed  1214  from the molding plates. Following the block  1214 , the ear tip formation process  1200  can end. 
     In another embodiment an ear tip can include a filter for substantially blocking foreign matter.  FIG. 13  is a cross-sectional view of the ear tip  1300  according to another embodiment of the invention. The ear tip  1300  is generally configured the same as the ear tip  900  illustrated in  FIG. 9E . Additionally, the inner structure  904  further includes a filter  1302 , such as a mesh. The filter  1302  can be supported by a filter support  1304 . The filter  1302  can be provided proximate to the front surface  908  of the ear tip  1300 . The filter  1302  can, for example, be formed of metal, such as stainless steel, or a polymer, such as nylon. The filter support  1304  can, for example, by a polymer, such as nylon. In one implementation, the filter  1302  and the filter support  1304  can be molded into the inner structure  904 . The filter supports  1304  can serve to minimize any injection molding material from attaching to the filter  1302  during the molding process (i.e., injection molding). 
     The various aspects, features, embodiments or implementations of the invention described above can be used alone or in various combinations. 
     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: 20080905
Publication Date: 20120911
Grant Date: 20120911
Priority Date: 20071019
Inventors: STIEHL KURT
TISCARENO VICTOR
FRAZIER CAMERON
Assignee: APPLE INC
CPC Classifications: [{"code": "B29C45/0055", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C45/0025", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29L2031/753", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C67/0018", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C2045/0034", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C45/1676", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/1016", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04R1/1058", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 40562335