WO2015107361A1

WO2015107361A1 - Ear-dock for mounting to an earphone

Info

Publication number: WO2015107361A1
Application number: PCT/GB2015/050098
Authority: WO
Inventors: Paul Dominique Philip JOBIN
Original assignee: Jobin Paul Dominique Philip
Priority date: 2014-01-16
Filing date: 2015-01-16
Publication date: 2015-07-23
Also published as: GB201400720D0

Abstract

An ear-dock for mounting to a spigot of an earphone of a set of headphones is described. The set of headphones are selected by an individual. The ear-dock comprises an ear-sleeve having a cavity and a contoured external surface shaped to match the ear canal of the individual and an intermediate sleeve comprising a body with a first end and an opposing second end. The intermediate sleeve further comprises a socket at the first end, where the socket is shaped to match and cooperate with the shape of the spigot of the earphone of the selected headphones. The ear-sleeve and the intermediate sleeve are assembled together by the second end of the body being received in the cavity.

Description

EAR-DOCK FOR MOUNTING TO AN EARPHONE

FIELD OF THE INVENTION

[1] This invention relates to headphones. In particular, this invention relates to in-ear headphones.

BACKGROUND

[2] Headphones that are intended to sit in the ear itself have small earphones that rest in the outer ear. In contrast, in-ear headphones have small earphones that are fitted into the ear canal of the user. This allows the earphone to be more easily retained in the ear and can lessen the impact of environmental noise on sound quality. Usually these earphones are provided with earbuds that are soft and are squashed into, and intended to conform to, the ear canal. The buds usually come in small, medium and large sizes and are rem oveably fitted to the earphones.

[3] Instead of earbuds, a bespoke earpiece that matches the exact three-dimensional profile of the ear canal of a user can be used. This makes an air-tight fit with the ear canal and further improves the isolation of the sound delivered to the wearer from the background environmental noise.

[4] Manufactured earpieces are unique to each user since each person's ear canal is different from another person. Each uniquely shaped earpiece must also be matched to that user's desired headphone manufacturer. For commercial reasons the earphones of each headphone manufacturer tend to have distinct features that interface with the manufacture's earbuds. Hence, a user must select his preferred headphone manufacturer at the same time as having an impression of his ear canal taken. The earpiece must then be moulded using interface dimensional data selected from the known interfaces of a myriad of headphone manufacturers. This adds cost to the manufacturing process of bespoke earpieces.

[5] Thus, there is a need to provide an improved bespoke earpiece for in-ear headphones that is both more useful and readily available to headphone users and provides an improved manufacturing process.

SUMMARY OF THE INVENTION

[6] According to a first aspect of the invention there is provided an ear-dock for mounting to a spigot of an earphone of a set of headphones, the set of headphones being selected by an individual. The ear-dock comprises an ear-sleeve having a cavity and a contoured external surface shaped to match the ear canal of the individual and an intermediate sleeve comprising a body with a first end and an opposing second end. The intermediate sleeve further comprises a socket at the first end, where the socket is shaped to match and cooperate with the shape of the spigot of the earphone of the selected headphones. The ear-sleeve and the intermediate sleeve are assembled together by the second end of the body being received in the cavity.

[7] According to another aspect of the invention a set of headphones selected by an individual is provided. The set of headphones comprises an earphone including a speaker for delivering sound to the ear canal. The earphone has a spigot through which the sound is delivered. The set of headphones also comprises an ear-dock as described herein in which the socket of the intermediate sleeve of the ear-dock is mounted to the spigot of the earphone.

[8] According to another aspect of the invention a method of manufacturing an ear-dock for mounting to a spigot of an earphone of a set of headphones is provided. The set of headphones are selected by an individual. The method comprises the steps of: providing an intermediate sleeve comprising a body with a first end and an opposing second end and further comprising a socket at the first end, where the socket is shaped to match and cooperate with the shape of the spigot of the earphone of the selected headphones; and overmoulding an ear-sleeve at the second end of the intermediate sleeve body in which the overmoulding process forms a cavity in the ear-sleeve and a contoured external surface shaped to match the ear canal of the individual and wherein the cavity accommodates the second end of the intermediate sleeve body.

[9] According to another aspect of the invention a method of assembling an ear-dock for mounting to a spigot of an earphone of a set of headphones is provided. The set of headphones are selected by an individual, the method comprising the steps of: providing an intermediate sleeve comprising a body with a first end and an opposing second end and further comprising a socket at the first end, where the socket is shaped to match and cooperate with the shape of the spigot of the earphone of the selected headphones and the intermediate sleeve further comprises a connecting feature at the second end of the body; providing an ear-sleeve having a cavity and a contoured external surface shaped to match the ear canal of the individual and the ear-sleeve comprises a complementary connecting feature; and assembling the intermediate sleeve and ear-sleeve together by engaging the connecting feature and the complementary connecting feature.

[10] A method of assembling an ear-dock may also include the further step of mounting the socket of the intermediate sleeve of the ear-dock to the spigot of the earphone of the set of headphones.

DESCRIPTION OF THE DRAWINGS

[1 1] The invention will now be described in detail with reference to the following drawings of which:

[12] Figure 1 is a view of an earphone with its generic earbud removed from its interface and an ear-dock having an outer surface corresponding to the impression of an ear canal of an intended user; [13] Figure 2 is a view of the earphone and ear-dock of Figure 1 in which the earphone and ear-dock are in the process of being mated together on the earphone's interface feature;

[14] Figure 3 is a view of the earphone and ear-dock of Figure 1 in which the ear-dock is fully mated on the interface of the earphone;

[15] Figure 4 shows the ear-dock of Figure 1 fitted to a set of headphones having the earphones of Figure 1 or Figure 5;

[16] Figure 5 shows an ear-dock according to the present invention which includes an ear- sleeve and an intermediate sleeve which are to be fitted over an earphone with its generic earbud removed;

[17] Figure 6 shows another view of the intermediate sleeve of the Figure 5; and

[18] Figure 7 shows another view of the ear-sleeve of the Figure 5.

[19] Throughout the drawings, like reference symbols refer to like features or steps.

DETAILED DESCRIPTION OF THE INVENTION

[20] This invention relates to a device for improving the fit of any earphone, by putting a soft Ear-Dock onto the sound outlet nozzle of the earphone. This modular Ear-Dock, as opposed to fully encased fitting, is the invention.

[21] Earphones are supplied with soft ear buds in different sizes, normally, small, medium and large. These generic buds are trying to create a tight and comfortable fit within the users ear. But the shape of the someone's inner ear canal is as unique and different as a finger print or eye retina.

[22] The only way to get an air-tight fit is to make an impression of one's inner ear canal and then to make a Ear-Dock that replicates that impression with a sound hole through the center of the Ear-Dock. You then insert the outlet nozzle of the earphone into sound hole that runs through the Ear-Dock.

[23] The Ear-Dock described is a moulded sleeve that attaches to any earphone, which makes the earphone perfectly fit the individual shape of the users ear canal. The Ear-Dock sleeve is made from an exact impression of the users ear canal deep enough to go just past the second bend in the ear canal.

[24] The Ear-Dock creates a perfect fit to the users ear canal by being a soft pliable material that creates an air-tight fit with the ear canal.

[25] The Ear-Dock sleeve must have an input aperture that is an exact fit with the output nozzle of the earphone. A variation is that there is an intermediary sleeve to allow the input nozzle of the Ear-Dock to be a single size. This intermediary sleeve has an input nozzle to fit a specific output nozzle of an earphone. This way only the intermediary sleeve needs to made specific for any particular earphone.

[26] The input nozzle of the Ear-Dock will be of a size to allow the fitting of a noise protection filter. [27] The input nozzle of the Ear-Dock will be of a size to allow the fitting of solid waterproof plug.

[28] It is noted that Figure 1 shows an earphone (in this case an Etymotic HF-3) with it's generic ear bud removed. The earphone outlet nozzle is positioned at the entry point to the Ear- Dock which is an exact impression of the patent applicants inner ear canal.

[29] It is noted that Figure 2 shows the outlet nozzle of the earphone just entering the sound channel hole that runs through the centre of the Ear-dock.

[30] It is noted that Figure 3 shows the outlet nozzle of the earphone fully inserted in the Ear- dock. The dotted line shows the position of the outlet nozzle within the Ear-dock.

[31] It is noted that Figure 4 shows a complete earphone (in this case an Etymotic HF-3) with both Right and Left Ear-Docks fitted.

[32] It is noted that Figure 5 shows an earphone (in this case an Etymotic HF-3) with it's generic ear bud removed. The earphone has an intermediate sleeve over it's outlet nozzle which allows the input nozzle of the Ear-Dock to be a single size, no matter what earphone is used.

[33] The invention will now be discussed in further detail with reference to the features of the headphones, earphones and ear-dock as indicated by appropriate reference signs in the Figures.

[34] Referring to Figure 1 , an earphone 10 of the Etymotic HF-3 type is shown, but it could be an earphone of any desired manufacturer. The earphone 10 has a spigot 12 that could also be known as a stalk or output nozzle. The spigot 12 includes an interface 14 that is intended to be mated with the manufacturer's generic earbud (not shown). In this case the interface 14 has an undercut 16 or ledge that acts to retain the generic earbud.

[35] The earphone 20 includes a speaker that generates the sound to be delivered to the ear. The earphone 20 also includes an opening or passage through which the sound is delivered. Neither the speaker nor the passage are shown. The earphone 20 also includes an electical cable 18 to connect the earphone 20 to the input jack that receives the output sound electrical signal and delivers it to the speaker in the earphone 20.

[36] Figure 1 also shows an ear-dock 20 that is intended to be mated with the earphone 10 via spigot 12 and interface 14. The ear-dock 20 could also be referred to as an earpiece or in-ear monitor, all of which are interchangeable terms.

[37] The ear-dock 20 has contoured external surface 22 or a three-dimensional outer surface that has been manufactured to match the ear canal impression of an intended user of the headphones to which the earphone 10 belongs. The ear-dock 20 includes a socket 24 that complements and can mate with the spigot 12 and interface 14 of the earphone 10. The socket 24 is shaped to match the spigot 12 of the earphones 10. Specifically, the socket 24 is shaped to match the spigot 12 of the earphone 10 that is desired by the intended user of the earphone. In other words, the user must specify the earphone manufacturer that the ear-dock 20 is to be assembled with and the ear-dock 20 socket 24 is shaped accordingly to match that particular spigot 12. In the case of the earphone 10 in this example, the socket 24 has a complementary undercut 26 that cooperates with the undercut 16 of the interface 14 so that the ear-dock is retained on the spigot 12.

[38] The ear-dock 20 includes a passage or channel (not shown) that runs through the middle of the ear-dock 20. The passage delivers sound from the earphone 10 spigot 12 to the ear canal of the user. One end of the passage is in communication with the socket 24 to receive the sound generated by the earphone 10 speaker. The other end of the ear-dock 20 passage is adapted to be in communication with the ear canal of the user when the ear-dock 20 is inserted into the canal.

[39] Figure 2 shows the ear-dock 20 partially mated with the spigot 12 of earphone 10. This is achieved by pushing the socket 24 of ear-dock 20 over the interface 14 of the spigot 12. The engagement of the socket 24 of the ear-dock 20 with the spigot 12 of earphone 10 is a push-fit engagement. In Figure 3, it can be seen that the ear-dock 20 has been pushed fully over the spigot 12 so that the complementary undercut 26 of the socket 24 engages the undercut 16 of the interface 14. In this way, the ear-dock 20 is securely retained on the earphone 10.

[40] Figure 4 shows a completed set of headphones 100 that includes left and right earphones 10L, 10R as described above. The headphones 100 also include left and right ear- docks 20L, 20R that have contoured external surfaces 22 that match the left and right ear canal impressions of an intended user. The earphones 10L, 10R have cables 18L, 18R that join the jack 120 via a main cable 1 10. In this case the headphones 100 are of the Etymotic HF-3 type, but could be of a type from any desired manufacturer of headphones. The ear-docks 20L, 20R could be of the type described above with respect to Figures 1-4 or of those described below with respect to Figures 5-7.

[41] Figure 5 shows an ear-dock 20 according the present invention. The ear-dock is to be mated to the earphone 10. As with Figures 1-5, the earphone 10 is of the Etymotic HF-3 type, but it could be an earphone of any desired manufacturer. As above, the earphone 10 has the same spigot 12 that could also be known as a stalk or output nozzle. Although not shown, the spigot 12 also includes the interface 14. The spigot 12 and the interface 14 will vary in shape according to the earphone 10 user's selected manufacturer of headphones.

[42] The ear-dock 20 includes an ear-sleeve 30 and an intermediate sleeve 40. In Figure 5, the ear-dock 20 is shown in an unassembled form where the ear-sleeve 30 and intermediate sleeve 40 are separated. The ear-dock 20 is to be mounted on the spigot 12 of earphone 10 by way of the intermediate sleeve 40. The spigot 12 is obscured in Figure 5 by the intermediate sleeve 40.

[43] Referring also to Figures 6 and 7, which, in more detail, show the intermediate sleeve 40 and the ear-sleeve 30 respectively. The intermediate sleeve 40 has a body 41 , a first end 42 and am opposing second end 48. At the first end 42 of the intermediate sleeve 40 a socket 44 is provided. The socket 44 complements and can mate with the spigot 12 and interface 14 of the earphone 10. The socket 44 is shaped to match the spigot 12 of the earphones 10. The shaping of the socket 44 depends upon the selection of earphone 10 manufacturer by the ultimate user of the headphones. Once the user's desired manufacturer of the headphones is known then an intermediate sleeve 44 having the appropriately shaped socket 44 can be combined with the ear- sleeve 30 to create the complete ear-dock 20. The ear-dock 20 then matches both the user's ear canal impression (left or right) and the user's desired manufacturer of headphones.

[44] For the example given in Figures 5-7, the socket 44 of the intermediate sleeve 40 has a complementary undercut 46 that cooperates with the undercut 16 of the interface 14 so that the ear-dock 20 is retained on the spigot 12. The undercut 46 may not be present on other sockets 46 that are shaped to match spigots 12 of alternative manufacturers. Instead, differing spigot 12 shapes and interface 14 features, which are designed to retain the particular manufacturer's earbuds, will be present on the earphone 10 and the socket 44 of the intermediate sleeve 40 must be shaped accordingly.

[45] At the second, opposing, end 48 of the intermediate sleeve 40, a standardised connecting feature 50 may be provided on the body 41 intermediate sleeve 40. As explained further below, the connecting feature 50 may be provided to allow the ear-sleeve 30 to be assembled to the intermediate sleeve 40. As explained below, the assembly may rely solely on the body 41 of the intermediate sleeve 40. The connecting feature 50 is entirely independent and unrelated to the socket 44 at the first end 42 of the independent sleeve 40. In other words, irrespective of the shape of socket 44, which is dependent on the selected earphone 10 manufacturer, the connecting feature 50 can be the same on the variety of manufacturer specific intermediate sleeves 40. Optionally, the connecting feature 50 may simply be a smooth surface that blends with the body 41 of the intermediate sleeve 40. Thus, the connecting feature 50 may be very small or indistinguishable from the body of the intermediate sleeve 40. In other words, the connecting feature 50 is optional.

[46] The ear-sleeve 30 is provided with a cavity 34 that is able to receive the body of the intermediate sleeve 40 when the ear-sleeve 30 and intermediate sleeve 40 are assembled together. The cavity 30 forms an opening in the ear-sleeve 30 so that the intermediate sleeve 40 may be inserted into the ear-sleeve. In other words, the cavity 30 forms a hole in the ear-sleeve 30. The cavity 34 may include a complementary connecting feature 38 that engages the optional connecting feature 50 of the intermediate sleeve 40 on assembly. When present, the connecting feature 50 and complementary connecting feature 38 act to ensure the ear-sleeve 30 is retained on the intermediate sleeve 40. Because the ear-sleeve 30 is retained on the intermediate sleeve 40 it is also securely retained on the earphone 10.

[47] As with the connection feature 50 on the intermediate sleeve 40, the complementary connecting feature 38 may be very small or absent from the cavity 34. Such an arrangement would allow the ear-sleeve 30 and intermediate sleeve 40 to be unassembled with little effort and so to allow an easy interchange of the intermediate sleeve 40 with an alternative intermediate sleeve 40. Thus, a user could change earphone 10 and headphone manufacturer very easily without undue effort. [48] However, it is preferable that connection feature 50 and complementary connecting feature 38 are provided since it ensures that the ear-sleeve 30, intermediate sleeve 40 and earphone 10 are secured effectively to each other on assembly.

[49] The ear-sleeve 30 is also provided with contoured external surface 32 or a three- dimensional outer surface that has been manufactured to match the left or right ear canal impression of an intended user of the headphones to which the earphone 10 belongs. The contoured external surface 32 allows a good air-tight fit with the ear canal of the user so as to improve sound performance of the earphone 10.

[50] The intermediate sleeve 40 also has a passage 52 that is in communication with the socket 44 and forms an aperture at the second end 48. Thus, sound from the earphone 10 speaker can be delivered through the intermediate sleeve 40. A second passage (not shown) is also provided through the middle of the ear-sleeve 30. This second passage delivers sound from the passage 52 of the intermediate sleeve 40 to the ear canal of the user. One end of the passage is in communication with the aperture formed by the passage 52 at the second end of the intermediate sleeve 40 to receive the sound generated by the earphone 10 speaker. The other end of the ear-sleeve 30 passage is adapted to be in communication with the ear canal of the user when the ear-dock 20 is inserted into the canal.

[51] Because the ear-dock 20 of the invention is provided with an ear-sleeve 30 and an intermediate sleeve 40, the manufacturing of the ear-dock 20 can be simplified and therefore results in time and cost savings. Providing the ear-dock 20 with an intermediate sleeve 40 that supports the ear-sleeve 30 means that a variety of intermediate sleeves 40 can be produced having varying socket 44 shapes according to the range of earphones 10 produced by various manufacturers. The body 41 and the connecting feature 50 of the intermediate sleeve 40, in conjunction with the cavity 34 and complementary connecting feature 38 of the ear-sleeve 30, can be standardised. Thus, these features will be the same for all intermediate sleeves 40, irrespective of manufacturer, so that the ear-dock 20 production is more flexible and cost- effective.

[52] Thus, to manufacture the ear-dock 20, the ear-sleeve 30 is manufactured having the required contoured external surface 32 of the intended user and the standardised cavity 34. If desired, the standardised complementary connecting feature 38 can also be provided on the cavity 34 to match any connecting feature 50 on the intermediate sleeve 40. The appropriate intermediate sleeve 40 that has the correctly shaped socket 44 matching the user's chosen earphone 10 manufacturer is then selected. The ear-sleeve 30 is then assembled to the selected intermediate sleeve 40 to complete the ear-dock 20 that fits to the earphone 10 of the user's chosen headphone manufacturer.

[53] Because a variety of intermediate sleeves 40 can be produced having varying socket 44 shapes according to earphone 10 manufacturer whilst having a standardised body 41 (and standardised connecting feature 50 if desired), the manufacture of the ear-sleeve 30 be standardised as far as possible. Thus, the only manufacturing variable for the ear-sleeve 30 is the contoured external surface 32 which must match the impression of the intended user's ear canal.

Thus, manufacture of the ear-dock 20 is made easier, flexible and more cost-effective.

[54] Once the ear-dock 20 is assembled, the intermediate sleeve 40 can be assembled to the spigot 12 of earphone 10. This is achieved by pushing the socket 44 of the intermediate sleeve

40 over the interface 14 of the spigot 12. The engagement of the socket 44 of the ear-dock 20 with the spigot 12 of earphone 10 is a push-fit engagement. Where an undercut 16 is provided on the interface 14 of certain earphones 10, then the complementary undercut 46 of the socket 44 engages the undercut 16 of the interface 14 when the ear-dock 20 has been pushed fully over the spigot 12. The intermediate sleeve 40 therefore retains the ear-dock 20 on the earphone 20.

[55] The ear-sleeve 30 and intermediate sleeve 40 can be assembled together in a number of different ways depending on the desired arrangement of the ear-dock 20.

[56] The connecting feature 50 and complementary connecting feature 38 can be adapted to provide for a push-fit connection between the ear-sleeve 30 and the intermediate sleeve 40.

Figure 6 shows an example of such an arrangement where the connecting feature 50 is a rib surrounding the second end 48 of the intermediate sleeve 40.

[57] Alternatively, where no connecting feature 50 and complementary connecting feature 38 are provided, the ear-sleeve 30 cavity 34 simply slides over the intermediate sleeve 40 body 41.

[58] The ear-sleeve 30 could also be permanently assembled or joined to the intermediate sleeve 40. For example, the ear-sleeve 30 could be over-moulded on to the intermediate sleeve 40 body 41. To this end the connecting feature 50 can be adapted to ensure the over-moulding process retains the ear-sleeve 30. For example, the connecting feature 50 can have undercuts that allow catch features to form in the ear-sleeve 30. Thus, the over-moulding process itself forms the complementary connecting feature 38 as the ear-sleeve 30 is formed about the intermediate sleeve 40. In another example, the connecting feature 50 could be a series of holes formed in the intermediate sleeve 40 in a direction transverse to the sound passage 52.

[59] Alternatively, the connecting feature 50 could be a bonding agent that permanently holds the ear-sleeve 30 to the intermediate sleeve 40. Other bonding methods could also be used to hold the ear-dock 20 together.

[60] The ear-sleeve 30 may be constructed from silicone or another suitably mouldable elastomer. The intermediate sleeve 40 may also be constructed from silicone or another suitably mouldable elastomer. Where the intermediate sleeve 40 is constructed from silicone or another suitably mouldable elastomer, the grade of material used for the intermediate sleeve 40 may be harder or more rigid than that used for the ear-sleeve 30. Alternatively, the intermediate sleeve 40 may be a rigid plastics material so that the intermediate sleeve 40 'clicks' or 'bumps' over the interface 14 of the spigot 12.

[61] While the foregoing has described what are considered to be the best mode and/or other examples, it is understood that various modifications may be made therein and that the subject matter disclosed herein may be implemented in various forms and examples, and that the teachings may be applied in numerous applications, only some of which have been described herein. It is intended by the following claims to claim any and all applications, modifications and variations that fall within the true scope of the present teachings.

[62] Although the present invention has been described in terms of specific exemplary embodiments, it will be appreciated that various modifications, alterations and/or combinations of features disclosed herein will be apparent to those skilled in the art without departing from the spirit and scope of the invention as set forth in the following claims.

Claims

1. An ear-dock for mounting to a spigot of an earphone of a set of headphones, the set of headphones selected by an individual, the ear-dock comprising:

an ear-sleeve having a cavity and a contoured external surface shaped to match the ear canal of the individual;

an intermediate sleeve comprising a body with a first end and an opposing second end; the intermediate sleeve further comprising a socket at the first end, where the socket is shaped to match and cooperate with the shape of the spigot of the earphone of the selected headphones; and

the ear-sleeve and the intermediate sleeve assembled together by the second end of the body being received in the cavity.

2. An ear-dock according to claim 1 in which the intermediate sleeve further comprises a connecting feature at the second end of the body and the ear-sleeve comprises a complementary connecting feature wherein the ear-sleeve and intermediate sleeve are assembled together by the connecting feature being engaged with the complementary connecting feature.

3. An ear-dock according to any preceding claim in which the connecting feature and the complementary connecting feature provide a push-fit connection between the ear-sleeve and the intermediate sleeve.

4. An ear-dock according to any preceding claim in which the connecting feature is a rib at the second end of the intermediate sleeve body and the complementary connecting feature is shaped to cooperate with the rib.

5. An ear-dock according to claim 1 or claim 2 wherein the ear-sleeve is moulded over the second end of the intermediate sleeve body.

6. An ear-dock according to claim 5 when dependent on claim 2 wherein the connecting means includes a retaining feature to retain the ear-sleeve on the intermediate sleeve and the complementary feature is formed in the overmoulded ear-sleeve.

7. An ear-dock according to claim 6 wherein the retaining feature is a rib, an undercut or a transverse hole in the intermediate sleeve.

8. An ear-dock according to any preceding claim wherein the intermediate sleeve is a rigid plastics material or silicone or an elastomer.

9. An ear-dock according to any preceding claim wherein the intermediate sleeve is a material that is harder or more rigid than the material of the ear-sleeve.

10. An ear-dock according to any preceding claim in which the spigot of the earphone has an interface feature and the interface feature has an undercut and wherein the socket at the first end of the intermediate sleeve has a complementary undercut that is shaped to match and cooperate with the spigot interface feature so as to allow the ear-dock to be retained on the earphone.

1 1 . A set of headphones selected by an individual, the set of headphones comprising:

an earphone including a speaker for delivering sound to the ear canal;

the earphone having a spigot through which the sound is delivered;

an ear-dock according to any preceding claim wherein the socket of the intermediate sleeve of the ear-dock is mounted to the spigot of the earphone.

12. A set of headphones according to claim 1 1 in which the set of headphones includes a second earphone of opposite handedness to the first earphone, wherein a second ear-dock of opposite handedness to the first ear-dock is mounted to the spigot of the second earphone and the second ear-dock has a contoured external surface shaped to match the ear canal of the opposite handed ear of the individual.

13. A method of manufacturing an ear-dock for mounting to a spigot of an earphone of a set of headphones, the set of headphones selected by an individual, the method comprising the steps of:

providing an intermediate sleeve comprising a body with a first end and an opposing second end and further comprising a socket at the first end, where the socket is shaped to match and cooperate with the shape of the spigot of the earphone of the selected headphones; and

overmoulding an ear-sleeve at the second end of the intermediate sleeve body in which the overmoulding process forms a cavity in the ear-sleeve and a contoured external surface shaped to match the ear canal of the individual and wherein the cavity accommodates the second end of the intermediate sleeve body.

14. A method of assembling an ear-dock for mounting to a spigot of an earphone of a set of headphones, the set of headphones selected by an individual, the method comprising the steps of:

providing an intermediate sleeve comprising a body with a first end and an opposing second end and further comprising a socket at the first end, where the socket is shaped to match and cooperate with the shape of the spigot of the earphone of the selected headphones and the intermediate sleeve further comprises a connecting feature at the second end of the body;

providing an ear-sleeve having a cavity and a contoured external surface shaped to match the ear canal of the individual and the ear-sleeve comprises a complementary connecting feature; and

assembling the intermediate sleeve and ear-sleeve together by engaging the connecting feature and the complementary connecting feature.

15. A method of assembling an ear-dock, incorporating a method according to claim 13 or 14, comprising the step of:

mounting the socket of the intermediate sleeve of the ear-dock to the spigot of the earphone of the set of headphones.

16. An Ear-Dock that attaches to any earphone which makes the earphone perfectly fit the individual shape of the users ear canal.

17. An intermediary sleeve that fits between the earphone outlet nozzle and the Ear-Dock to allow any earphone to fit a single design of inlet in the Ear-Dock.

18. An Ear-Dock according to claim 17, which will allow the fitting of noise protection filter.

19. An Ear-Dock according to claim 17, which will allow the fitting of solid waterproof plug.