GB2504303A

GB2504303A - Earphones and customized earplugs

Info

Publication number: GB2504303A
Application number: GB201213173A
Authority: GB
Inventors: Tobias Murray Bateson; John Francis Dufort
Original assignee: Individual
Current assignee: Individual
Priority date: 2012-07-24
Filing date: 2012-07-24
Publication date: 2014-01-29
Anticipated expiration: 2032-07-24
Also published as: GB2504303B; GB201213173D0

Abstract

A system or kit for customized fitment to the ear of an earpiece for earphones comprises: a pre-formed thermoplastic inner earpiece 1 that is hollow, open at each end and adapted to be inserted into the ear and moulded in the ear of a user ; and a scaffold / adaptor 2 which is formed in a shape at one end to receive the earphone and that is ensheathed by the thermoplastic inner earpiece in use. The inner earpiece is suitably substantially frusto-conical in shape and preferably off-set. A special obturator tool or handle 3 is provided to facilitate the custom fitting process. The inner earpiece is formed of the low melting point thermoplastic polycaprolactone and so it can be moulded when heated in hot water. The combination of inner earpiece and adaptor will float in water, perhaps with the aid of a float ring (4, fig 6).

Description

Earphones and Earplugs

Field of the Invention

The present invention concerns improvements in and relating to earphones and earplugs to facilitate their customised fitting to a user's ear.

Background of the Invention

Earphones have gained in popularity over recent years with the inexorable spread of use of handheld audio gadgets such as mobile phones and especially smart phones and MP3 players such as Apple's ubiquitous iPod and other portable personal audio devices. Earphones are not only much more compact and conveniently portable and generally require much less energy to power than headphones or speakers, but also well engineered earphones can in some respects provide a higher quality audio experience than headphones or speakers, delivering a much higher proportion of generated sound waves into the user's ear and blocking out a higher proportion of ambient sound. Their successfulness in delivering a quality user experience owes much to their intimate fit to the user's ear but it is also often their Achilles heel.

The shape of the auditory canal of a user's ear varies from person to person and ear to ear and for a substantial number of users the fitment of earphones can be a source of substantial discomfort and especially where the earphone is moulded of relatively hard plastics and is not customised and doesn't suit the individual's ear topography. Both for user comfort and to enhance the audiophile experience higher quality earphones are now designed to be customised to the end user. UK patent GB2355129 discloses an adaptor to mount to an earphone at one end and coupling to a moulded inner earpiece at the other end. US patent 5,718,244 discloses an external ear occlusion device (earplug) having an improved deformable polycaprolactone material to be moulded to the ear canal.

In the present applicant's own earlier patent application GB 2,407177A we describe forming customised moulded earpieces or earplugs to fit into a user's ear canal, using a soft thermoplastic such as the polyester polycaprolactone with a low melting point to be pliable! mouldable in situ in the ear simply on pre-warming. The polycaprolactone polymer granules will melt and coalesce in a bath of hot water (at of the order of 62°C) and the polymer can then be formed into a ball and inserted into the ear. For earphones the soft thermoplastic earpiece can be made to have a central through hole for the passage of sound and to ensheathe a scaffold / earphone adapter that is of a relatively rigid plastics that is formed as a golf tee-shaped cap to clip onto the earphone and with a central spigot projecting distally from the cap into the ear to channel the sound from the earphone through the earpiece towards the through hole in the soft earpiece and hence into the ear.

This system provides for a relatively simple and efficient system for an end-user to self-customise their earpiece for fit in their ear, avoiding the need for a third party specialist and! or remote laboratory to carry out the customisation of the earpiece and considerably reducing the costs and delays that are normally associated with providing customised earphones or, for that matter, in providing customised hearing aids or other such auditory aids! appliances. However, there can be issues of reliability, with risk of occlusion of the central passage and the process may not suit those with limited abilities and limited manual dexterity. The need thus remains for a system that is truly DIY being reliable and suitable for self-customisation even by those with limited abilities. The present invention thus seeks to address these problems and improve reliability of the system to enable it to be rolled out as an effective DIY solution for customisation.

Summary of the Invention

According to a first aspect of the present invention there is provided a system for customized fitment to the ear of an earpiece for earphones or for other auditory equipment for sound delivery into the ear of a user, wherein the system comprises: i) a pre-formed, preferably tapering-shaped (e.g. substantially conical! frusto-conical), thermoplastic inner earpiece that is hollow and open at each end, having a relatively large opening at a proximal end that is outermost from the ear in use and a smaller through hole for the passage of sound at its distal end that is innermost in the ear in use, the inner earpiece being adapted to be inserted into the ear and moulded in the ear of a user; and ii) a scaffold / adaptor which is formed in a shape at the proximal end to receive the earphone or other auditory equipment to receive sound therefrom and that is ensheathed by the thermoplastic inner earpiece in use.

The pre-formation of the inner earpiece as a tapered hollow plug of thermoplastic, that is suitably of a low melting point thermoplastic, greatly facilitates the correct orientation and fit in the ear and aids the moulding process by reducing the degree to which the plastic needs to deform in order to conform to the user's ear when custom moulding the ear-piece in situ to fit the user's ear.

Preferably the adaptor has a concave/rounded bell or cup-shaped form facing outwardly at the proximal end to cup over the earphone or other auditory equipment. The rim of the bell or cup-shaped form may be adapted to clip over a rim of the earphone or other auditory equipment. The adaptor preferably has an undercut/ shoulder! flange proximate the rim of the cup part of the adaptor to aid attachment of the earphone. Preferably a ridge is provided within the cup pad of the adaptor to stop earphone moving about in cup.

Preferably the adaptor has a spigot / pipe-like conduit projecting distally to channel the sound from the earphone through the inner earpiece towards the through hole in the inner earpiece and hence into the ear. The adaptor preferably has one or more protrusions from its spigot! conduit to aid fixation of the inner ear piece. The, or each, protrusion may suitably comprise a raised circumferential ridge or flange.

The adaptor preferably has a groove in the spigot! conduit to allow air escape.

The preformed substantially conical! frusto-conical soft thermoplastic earpiece is particularly preferably formed to an offset! eccentric substantially conical or frusto-conical shape where the central axis of the distal end opening is offset from the central axis of the proximal end opening.

To greatly facilitate! further facilitate the reliable moulding of the thermoplastic inner earpiece for the user's ear, the system particularly preferably comprises an obturator. The obturator is a substantially rigid plug that plugs the proximal end opening of the adaptor. This preferably has a handle projection on the proximal! outer side thereof in use to aid holding of the device for insertion of the earpiece, for holding it in place during the moulding step and for removal.

Part of the obturator preferably has the form of a disc that corresponds closely in shape and size to the proximal opening of the adaptor plugging the opening in use and preventing distortion of the proximal end of the adaptor and inner earpiece, such as might occur from the user pressing their thumb in the cup of the adaptor during the in situ moulding.

The obturator particularly preferably has an elongate distal protrusion that extends into the spigot! pipe-like conduit of the adaptor. This has the form of a column. It suitably substantially fills the hollow interior of the spigot! pipe-like conduit of the adaptor and serves to substantially prevent any backflow of plastics that might block the conduit during the customisation moulding step. It also aids the correct positioning of the device and aids the correct orientating of applied manual pressure. The obturator may be provided as a second aspect of the invention for use to custom mould a thermoplastic inner earpiece. The obturator is buoyant and when fitted to the adaptor and inner ear piece enables them to float therewith in the hot water bath, enabling the user to fish the assembly from the water surface with ease without need to endure the discomfort of reaching down into the potentially scalding hot water to retrieve it.

The inner earpiece is particularly preferably a thermoplastic with a melting point below 10000 so that it may be plasticised in hot water by a user. Each of the adaptor and the obturator is preferably of a plastics polymer that has a substantially higher melting point than that of the inner earpiece. Accordingly they will not be significantly plasticized by the level of heat used to plasticize and mould the inner earpiece by the user. The adaptor and! or the obturator may suitably be of nylon or polypropylene, for example, both having melting points well above 100°C, or less suitably even polyethylene which is just above 10000.

In variants of the first aspect of the invention the kit! system may be adapted to serve for custom moulding of an earplug for blocking of sound rather than for transmitting sound. Those and further aspects of the invention will become apparent from the description and drawings that follow and from the accompanying claims.

Brief Description of the Drawings

Preferred embodiments of the invention will now be more particularly described, solely by way of example, with reference to the accompanying drawings in which: Figure IA is an isometric view of an adaptor! scaffold of the first preferred embodiment of the system of the invention, Figure lB is a side elevation view thereof and Figure IC is a distal end elevation view thereof; Figure 2A is an isometric view of an obturator (fitting tool) of the first preferred embodiment of the system of the invention, Figure 2B is a side elevation view thereof and Figure 2C is a distal end elevation view thereof; Figure 3A is an isometric view of an inner earpiece of the first preferred embodiment of the system of the invention, Figure 3B is a side elevation view thereof and Figure 3C is a proximal end elevation view thereof;; Figure 4A is an isometric view of the obturator being inserted into the proximal end of the adaptor, Figure 4B is an isometric view of the obturator fully inserted into the adaptor and Figure 4C is a side elevation view of the same; Figure 5A is a side elevation view of the assembly of the first preferred embodiment with the obturator in the adaptor and the adaptor inserted mi ensheathed by the earpiece as it is when it is used to insert the warmed up mouldable earpiece into the ear for the custom moulding in situ, and Figure 5B is a side elevation view of the Figure 5A assembly following withdrawal from the ear and removal of the obturator allowing the illustrated earphone to be push-fit mounted in the proximal end opening of the adaptor; Figure 6A is an isometric exploded assembly view of a second preferred embodiment comprising a sound blocking earplug that is mouldable in situ for custom fitting, showing the earplug assembly as comprising a tapered inner ear piece, an adaptor and an obturator plus an intermediate float ring that may be used to further assist floating the assembly in a hot water bath, Figure 6B is a side elevation view of the Figure 6A exploded assembly, Figure 6C is an isometric view of the Figure 6A assembly as assembled together, Figure 6D is a side elevation view corresponding to Figure 6C, and Figure 6E is an isometric view corresponding to Figure 6D but with float ring removed and obturator detached; Figure 7A is an isometric exploded assembly view of a variant of the second preferred embodiment having a domed cap obturator with a drawstring rather than a rigid handle, Figure 7B is a side elevation view of the Figure 7A exploded assembly, Figure 7C is an isometric view of the Figure 7A assembly with the adaptor and earplug assembled together but flat removed, Figure 70 is a side elevation view corresponding to Figure 7C, Figure 7E is an isometric view corresponding to Figure 7D but with the obturator attached, and Figure 7F is a side elevation view of the same.

Description of the Preferred Embodiment

Referring to figures 1 to 4, the first preferred embodiment of the invention comprises a custom fit system for an earpiece for earphones. The earphones can be of any type or for any purpose. They may, for example, be earphones of an iPodor other MP3 player. The system is embodied in a kit that comprises three main elements: a pre-formed inner earpiece 1; an adaptor 2 that serves as an interface between the earphone and earpiece in use; and an obturator 3 for manipulating the assembly during the custom fit moulding process.

The inner earpiece 1 as shown in Figures 3A-C is moulded to a generally frusto-conical shape that is hollow and open at each end, having a relatively large opening at a proximal end la that is outermost from the ear in use to aid sound transmission and a smaller through hole ic for the passage of sound at its distal end that is innermost in the ear in use. The openings are preferably substantially circular to match the substantially circular shape of the external auditory meatus of users' ears. The generally frusto-conical shape is not symmetrical but rather is off-set, which is to say that the axis of the proximal end opening la and the axis of the distal end through hole ic are not aligned with each other but are offset parallel to each other. This better conforms the ear-piece to the ear's general shape prior to fitting.

The pre-formed inner earpiece 1 is of a low melting point thermoplastic such as polycaprolactone which becomes deformable at 62 degrees and so can be softened in hot water and finish-moulded for individual customised fit directly in the ear canal. The polycaprolactone hollow frusto-conical form can thus adjust to the contours within the user's ear and then harden on cooling to body temperature. The moulding suitably incorporates antibacterial chemicals, such as incorporating Microban.

The adaptor 2 of Figures lA-C provides a substantially rigid frame! scaffold that prevents collapse! distortion of the general shape and internal air passageway of the earpiece 1 during the fitting process. The adaptor 2 is ensleeved by the moulded earpiece 1 at one end and fits as a cap over the MP3 player earphone

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at the other, thus avoiding having the thermoplastic earpiece 1 being moulded directly onto the earphone, as might damage it.

The thermoplastic earpiece 1 forms a sheath that covers the radially outer surface of the adaptor 2. The proximal end la of the earpiece 1 and proximal end 2a of the adaptor 2 each have a rounded concave interior 1 b, 2b leading to an offset smaller opening ic, 2c in the distal end of the earpiece 1 and adaptor 2, respectively. In the earpiece there is a groove id leading into the opening ic.

External convexity of the distal end of the earpiece 1 serves to conform it to the adaptor and aid flow and moulding of the polycaprolactone.

The adaptor 2 has the form of a domed! approximately hemispherical cup at its broad proximal end 2a and at the distal end the narrow distal opening 2c extends to form a cylindrical tube! spigot 2d. The cylindrical tube! spigot 2d has three annular ribs! flanges 2e therealong onto which the polycaprolactone of the ear-piece grips. A groove may be provided in the spigot! conduit 2d to allow air escape. An undercut is provided adjacent the rim of the proximal end 2a! cup part 2b of the adaptor 2 to facilitate clipping attachment of an earphone to the adaptor. The proximal end 2a! cup part of the adaptor 2 further has a ridge! shoulder 2f in the cup 2b to stop the earphone moving about in the cup. The interior of the cup of the adaptor 2 has a funicular! funnel shape to aid sound channelling. The wideness of the proximal end opening 2a and cup 2b shape aids acoustics.

Turning to Figures 2A-C, the third component of the kit! system here is the obturator 3. The obturator 3 fits inside the adaptor 2 to prevent incorrect moulding! distortion of the adaptor 2! earpiece 1 assembly from the softening in hot water and insertion into the ear. It facilitates correct application into the ear canal, ensuring that the user can apply the required manual pressure in the correct direction and without their thumb or fingers distorting the proximal end of the adaptor 2 and earpiece 1 assembly. It also prevents backflow of thermoplastic into the adaptor 2 and earpiece 1 assembly. The obturator 3 comprises a rigid solid circular discoidal body 3a to plug the proximal opening 2a of the adaptor 2 and thereby hold its shape and the shape of the proximal opening la of the earpiece 1. A fin-shaped handle grip 3b extends in the proximal direction from the discoidal body 3a, while a substantially circular cylindrical column 3c extends in the distal direction from the body 3a and is adapted to insert snugly into the passage of the tubel spigot 2d of the adaptor 2. To allow air to exit the ear as the assembly is inserted into the ear the column 3c of the obturator 3 has an elongate recess/groove 3d therealong on each side and also a part of the rim of the discoidal body 3a of the obturator 3 is truncated 3e to provide an air gap. The design of the obturator also facilitates water removal from the assembly as the column of the obturator inserts into the tube 2d of the adaptor 2. A further useful feature of the assembly including the earpiece 1, adaptor 2 and obturator 3 is that it is buoyant in the hot water bath to enable it to be plucked from the surface of the hot water bath before being inserted into the user's ear. In of use of the device to assist the custom-moulding process the user may first apply a greasing/lubricating agent such as Vaseline in the ear or on the earpiece 1, adaptor 2 and/ or obturator 3 before inserting the device into the ear to aid moulding, create a cleaner finish and ease removal from the ear.

Referring to Figures 6A-6E, these Figures show a second preferred embodiment of the invention, here comprising a sound blocking earplug suitable for use by light sleepers or those who work in noisy environments. The earplug is mouldable in situ for custom fitting. The earplug assembly comprises a tapered/ substantially frusto-conical inner ear piece 1' albeit closed/ not with a distal end opening, unlike the afore-described earphone4itting embodiment.

The earplug assembly further comprises an adaptor 2' and an obturator 3' plus an intermediate float ring 4 of neoprene foam that may be used to further assist floating the assembly 1', 2', 3' in a hot water bath. Whereas without the float ring 4 the assembly has some buoyancy and can be sufficient to float the lighter earphone mounting embodiment, in the more dense! weightier earplug embodiment the float ring 4 gives extra buoyancy to ensure flotation. The float ring 4 fits around the proximal end rim of the inner earpiece 1' and suitably acts like a jubilee clip to hold the adaptor 2' in place on the earplug earpiece 1' so that the latter does not detach from the adaptor 2' in the hot water bath.

The adaptor 2' of the earplug has a short circular cylindrical proximal end 2a' and a short spigot 2b' projecting distally that fits into a shallow circular cylindrical recess! cavity in the proximal end of the earpiece 1'. The obturator 3' for the earplug is similar to that of the earphones embodiment in having a discoidal body 3a' and a fin-shaped handle grip 3b' but lacks the distal column.

The obturator 3' pops off once the device has been moulded to conform to the user's ear and the float 4 then readily detaches too.

In a variant of the second embodiment illustrated in Figures 7A-7F the illustrated earplug assembly differs in comprising a domed cap as obturator 3' and which has a nylon or string cord 5 anchored at one end in the cap to facilitate handling. :ii

Claims

Claims 1. A system or kit for customized fitment to the ear of an earpiece, wherein the system or kit comprises: i) a pre-formed thermoplastic inner earpiece having a relatively large opening at a proximal end that is outermost from the ear in use, the inner earpiece being adapted to be inserted into the ear and moulded in the ear of a user; and ii) a scaffold I adaptor which is at least partially ensheathed by the thermoplastic inner earpiece in use, being received in a proximal end opening of the inner earpiece.
2. A system or kit for customized fitment to the ear of an earpiece as claimed in claim 1, wherein the earpiece is for earphones or for other auditory equipment for sound delivery into the ear of a user, wherein the pre-formed thermoplastic inner earpiece is hollow and open at each end, with the relatively large opening at the proximal end and a smaller through hole for the passage of sound at its distal end that is innermost in the ear in use; and the scaffold / adaptor is formed in a shape at the proximal end to receive the earphone or other auditory equipment to receive sound therefrom.
3. A system or kit as claimed in claim 1 or 2, wherein the inner earpiece is pre-formed to be tapering-shaped.
4. A system or kit as claimed in claim 3, wherein the inner earpiece is pre-formed to be to an offset! eccentric substantially conical or frusto-conical tapered shape where the central axis of the distal end opening is offset from the central axis of the proximal end opening.
5. A system or kit as claimed in claim 2, wherein the adaptor has a concave/rounded bell or cup-shaped form facing outwardly at the proximal end to cup over the earphone or other auditory equipment.
6. A system or kit as claimed in any preceding claim, wherein the adaptor has a spigot! pipe-like conduit projecting distally.
7. A system or kit as claimed in any preceding claim, wherein the system further comprises an obturator for use in moulding the soft thermoplastic earpiece, the obturator comprising a substantially rigid plug that plugs the proximal end opening of the adaptor.
8. A system or kit as claimed in claim 7, wherein the obturator has a handle projection on the proximal! outer side thereof in use to aid holding of the device for insertion of the earpiece, for holding it in place during the moulding step and for removal.
9. A system or kit as claimed in claim 7 and 8, wherein the obturator has an elongate distal protrusion that extends into the spigot! pipe-like conduit of the adaptor and which has the form of a column that fits in the hollow interior of the spigot! pipe-like conduit of the adaptor.
10. A system or kit for customized fitment to the ear of an earpiece, wherein the system or kit comprises: a thermoplastic inner earpiece of a thermoplastic with melting point below ioo°c having an opening at a proximal end that is outermost from the ear in use, the inner earpiece being adapted to be softened in hot water, inserted into the ear and moulded in the ear of a user; and an obturator for use in moulding the soft thermoplastic earpiece, the obturator being a substantially rigid plug that plugs the proximal end opening of the earpiece or an adaptor that fits in the proximal end opening of the earpiece.
11. A system or kit as claimed in any preceding claim, wherein the inner earpiece is of polycaprolactone.
12. A system or kit as claimed in any preceding claim, wherein the adaptor is of a plastics polymer that has a substantially higher melting point than that of the inner earpiece.
13. A system or kit as claimed in claim any of the preceding claims having an obturator, wherein the obturator is of a plastics polymer that has a substantially higher melting point than that of the inner earpiece.
14. A system or kit as claimed in claim 10, wherein the earpiece is for earphones or for other auditory equipment for sound delivery into the ear of a user, wherein the pre-formed thermoplastic inner earpiece is hollow and open at each end, with the relatively large opening at the proximal end and a smaller through hole for the passage of sound at its distal end that is innermost in the ear in use.
15. A system or kit as claimed in any of claims 10 to 14, wherein the system! kit has a scaffold / adaptor which is at least partially ensheathed by the thermoplastic inner earpiece in use, being received in a proximal end opening of the inner earpiece.
16. A system or kit as claimed in claim any of claims 1, 3, 4 or 6 to 13 or 15, wherein the inner earpiece serves as an earplug to block sound from entering the ear.
17. A system or kit as claimed in any preceding claim, wherein the earpiece with adaptor and! or obturator is buoyant and floats in water.
18. A system or kit as claimed in claim 16 wherein a float ring is provided for floating the earplug in water.
19. A system or kit for customized fitment to the ear of an earpiece, the system or kit being substantially as hereinbefore described with reference to the accompanying drawings.