Embodiments of the present disclosure generally relate to custom-fit earpieces and methods for customizing an earpiece for use in a user's ear.
Audio devices allow users to receive audio content or audio information from various media sources, such as internet, video players, gaming devices, music playing platforms or other types of audio generating devices. Typical portable in-ear audio devices may include various tethered and wireless headphones or other similar devices. Some common types of in-ear audio devices include earphones, in-ear monitors, and hearing aids. Listening devices, such as earphones and in-ear monitors can be hard-wired or wirelessly connected to an audio source to listen to audio provided to the device.
It is generally preferable to customize the shape of an in-ear audio device to a user's ear, so that the in-ear audio device is comfortable to wear, the in-ear audio device is easily retained in the user's ear, and any surrounding ambient noise can be eliminated or controlled when the in-ear audio device is inserted within the user's ear. Traditionally, custom-fit in-ear audio devices have used a wax-molding process to tailor the in-ear audio device to the unique shape of a user's ear. Although this wax-molding process can achieve a well-fitting custom in-ear audio device for a user, the process can be time-consuming and expensive. The process may require the user to travel to a location where a business can perform the wax molding of the user's ear. Then the user must wait multiple days until the custom in-ear audio device can be produced based on the wax molding and then sent to the user.
Therefore, there is a need for an improved custom-fit in-ear audio device and method of customizing the in-ear audio device that overcomes the deficiencies described above.
Embodiments of the disclosure may provide an audio device that includes an audio assembly comprising an audio speaker, and an ear insert connected to the audio assembly. The ear insert may include a sleeve body, one or more light sources disposed inside the sleeve body, a sound tube disposed inside the sleeve body, wherein an output of the audio speaker is connected to an input of the sound tube, and a curable filler material disposed inside the sleeve body and around the sound tube, wherein the one or more light sources are disposed in the curable filler material.
Embodiments of the disclosure may provide an audio device that includes an audio assembly comprising an audio speaker, and an ear insert connected to the audio assembly. The ear insert may include a sleeve body, a light reflective coating disposed on an inner surface of the sleeve body, a sound tube disposed inside the sleeve body, wherein an output of the audio speaker is connected to an input of the sound tube, and a curable filler material disposed inside the sleeve body and around the sound tube, wherein the one or more light sources are disposed outside of the curable filler material and adjacent to a surface of a portion of the sleeve body which does not include the light reflective coating.
Embodiments of the disclosure may further provide an audio device comprising an audio assembly comprising an audio speaker, and an ear insert connected to the audio assembly. The ear insert may include a sleeve coated with a first reflective material, one or more light sources disposed inside the sleeve, a sound tube disposed inside the sleeve, wherein the sound tube is coated with a second reflective material and an output of the audio speaker is connected to an input of the sound tube, and a curable filler material disposed inside the sleeve and around the sound tube.
Embodiments of the disclosure may provide an audio device that includes an audio assembly comprising an audio speaker, and an ear insert connected to the audio assembly. The ear insert may include a sleeve body including an ear tip having an output to direct audio to the user, a first light source, a sound tube disposed inside the sleeve body, wherein an output of the audio speaker is connected to an input of the sound tube, a curable filler material disposed inside the sleeve body and around the sound tube, and a fiber optic cable extending from one of the first light source to an interior portion of the ear tip of the sleeve body.
Embodiments of the disclosure may provide an audio device that includes an audio assembly comprising an audio speaker and an ear insert connected to the audio assembly. The ear insert may include a sleeve body including an ear tip having an output to direct audio to the user, a first light source, a sound tube assembly including a base and a sound tube having a length extending from the base to an output region of the sound tube, wherein the sound tube assembly is disposed inside the sleeve body, an output of the audio speaker is connected to an input of the sound tube, and the sound tube includes a first portion, a second portion, and a third portion spaced apart from each other along the length of the sound tube, wherein the first portion and the second portion are each more optically transparent than the second portion and second portion is disposed between the first portion and the third portion, and a curable filler material disposed inside the sleeve body and around the sound tube.
Embodiments of the disclosure may provide a method of forming a customizable ear insert comprising forming a sound tube, overmolding a sleeve body onto the sound tube, inserting the sound tube into the sleeve body by turning the sleeve body outside out, and adding a curable filler material to the interior of the sleeve body.
Embodiments of the disclosure may provide a method of forming a customizable ear insert comprising inserting a sound tube into an inner volume of a flexible sleeve body, wherein the flexible sleeve body comprises an ear tip portion for providing audio to a user and a collar to retain the sound tube in the inner volume, inserting a first flat tube through the collar of the flexible sleeve body to connect the inner volume of the flexible sleeve body to an external environment, expanding the first flat tube with a first catheter, and adding a curable filler material to the inner volume of the flexible sleeve body through the first catheter.
Embodiments of the disclosure may further provide an audio device, comprising two earphone assemblies, wherein each of the two earphone assemblies comprises an ear insert and an audio assembly. Each of the ear inserts in the two earphone assemblies comprise a sleeve body having an inner surface, and comprising an elastic material and a reflective material which is configured to reflect one or more wavelengths of light emitted by a radiation source, a sound tube that is coupled to the sleeve body, wherein the inner surface of the sleeve body and an outer surface of the sound tube at least partially define an inner volume of the ear insert, and a curable filler material disposed within the inner volume, wherein the curable filler material is configured to be cured by the one or more wavelengths of light emitted by the radiation source. Each of the audio assemblies in the two earphone assemblies comprise an audio driver configured to deliver audible sound to an inner surface of the sound tube. An external surface of the sleeve body of the ear insert in a first of the two earphone assemblies has a shape that is different from a shape of an external surface of the sleeve body of the ear insert in a second of the two earphone assemblies.
Embodiments of the disclosure may further provide an audio device that comprises an earphone assembly. The earphone assembly comprises an ear insert and an audio assembly. The ear insert comprises a sleeve body having an inner surface, and comprising an elastic material and a reflective material which is configured to reflect one or more wavelengths of light emitted by a radiation source, a sound tube that is coupled to the sleeve body, wherein the inner surface of the sleeve body and an outer surface of the sound tube at least partially define an inner volume of the ear insert, and a curable filler material disposed within the inner volume, wherein the curable filler material is configured to be cured by the one or more wavelengths of light emitted by the radiation source. The audio assembly comprises an audio driver configured to deliver audible sound to an inner surface of the sound tube. The audio assembly can be separably coupled to the ear insert.
Embodiments of the disclosure may further provide an audio device that comprises an earphone assembly. The earphone assembly comprises an ear insert and an audio assembly. The ear insert comprises a sleeve comprising an elastic material and having an inner surface, a sound tube that is coupled to the sleeve, wherein the inner surface of the sleeve and an outer surface of the sound tube at least partially define an inner volume of the ear insert, a curable filler material disposed within the inner volume, wherein the curable filler material is configured to be cured by one or more wavelengths of light emitted by a radiation source, and a reflective coating disposed over the inner surface of the sleeve, wherein the reflective coating is configured to reflect the one or more wavelengths of light emitted by the radiation source. The audio assembly comprises an audio driver configured to deliver audible sound to an inner surface of the sound tube, and a portable power source configured to power the audio driver and the radiation source.
So that the manner in which the above recited features of the present disclosure can be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only exemplary embodiments and are therefore not to be considered limiting of its scope, and may admit to other equally effective embodiments.
To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. It is contemplated that elements and features of one embodiment may be beneficially incorporated in other embodiments without further recitation.
Embodiments of the present disclosure generally relate to custom-fit in-ear audio devices, also referred to herein as in-ear audio devices, custom-fit earpieces, or simply earpieces. The following discloses embodiments of custom-fit earpieces that include features providing superior retention in a user's ear while also maintaining desirable comfort and sound quality. The superior retention is generally provided by a curable filler material disposed in a sleeve that is deformed to conform to the shape of a user's ear as the curable filler material is cured. The comfort level of the custom-fit earpiece described herein is enhanced because at least a portion of the audio output member can move independently or relative to the portion of the earpiece that includes the curable filler material, thus allowing the audio output member to adjust to and comfortably fit within a given user's ear canal.
The following disclosure includes embodiments that can improve a custom-fit in-ear audio device by reducing the size and/or configuration of certain components in the portable in-ear audio device, and by improving the reliability of the process of forming the custom-fit in-ear audio device. For example, the disclosed improvements, such as a reflective sound tube and including radiation sources (e.g., light-emitting diodes) within a curable filler material can allow for smaller radiation sources to be used. These smaller radiation sources produce less heat than larger radiation sources, which can be safer and more comfortable for users during the curing process, and can also allow for smaller heat sinks to be used. The reliability of the custom-fit in-ear audio device can also be improved by reducing the variability in curing rates of a curable filler material disposed at different locations in the custom-fit in-ear audio device. Variability in cure rates at different locations within custom-fit in-ear audio device can cause mechanical stresses that prevent the curable filler material from properly bonding to the surrounding sleeve. The variability in cure rates can be reduced by providing light more directly to the ear tip portion of the custom-fit in-ear audio device (i.e., the portion of the device that extends into a user's ear canal). The following also discloses embodiments that can improve the manufacturing process of forming the custom-fit earpieces, for example by manufacturing the custom-fit in-ear audio device with less manufacturing steps making the custom-fit in-ear audio device less expensive to manufacture.
The audio device 100 includes two earphone assemblies 101. Each earphone assembly 101 includes a customizable ear insert 102 and an audio assembly 111. The two earphone assemblies 101 can be mirror images of each other so that one earphone assembly 101 is configured to be positioned within a user's left ear and one earphone assembly 101 is configured to be positioned within a user's right ear. The term “mirror image” as used herein is intended to describe components that are substantially similar to one another in an opposite orientation, and thus the term “mirror image” is not intended to be narrowly construed as an exact inverted copy.
The audio device 100 further includes a controller assembly 112 and a connection assembly 113. The controller assembly 112 and the connection assembly 113 are connected to each other and to the earphone assemblies 101 by one or more cables 114. The cables 114, which are generally flexible, are configured to physically couple the controller assembly 112, the connection assembly 113 and the earphone assemblies 101 together, and also allow the transmission of electrical signals through one or more wires that form part of the various links 231-233 (
The outer ear 20 includes an ear canal 2 leading to an ear drum (not shown). An ear lobe 1 forms a lower portion of the outer ear 20 and a helix 6 extends from the ear lobe 1 to a top portion of the outer ear 20. The ear canal 2 is surrounded by the cavum conchae 3, the crus helix 5, the tragus 10, and the antitragus 12. The cavum conchae 3 has a recessed shape (e.g., bowl shape) relative to the surrounding portions of the outer ear 20 other than the ear canal 2. The customizable ear insert 102 can be placed in this recessed shape of the cavum conchae 3 as more fully described below. The antitragus 12 is a projection extending from the ear lobe 1 towards the ear canal 2. The tragus 10 is a projection extending from the face (not shown) towards and/or over the ear canal 2. The crus helix 5 is a spiny portion extending from above the tragus 10 to the cavum conchae 3. The antihelix 8 is disposed between the helix 6 and the crus helix 5. The antihelix 8 is separated from the crus helix 5 by the cymba conchae 4, which is recessed relative to the crus helix 5 and the antihelix 8. The portion of the antihelix 8 that is connected to the cymba conchae 4 is the crus antihelicis inferioris 14. The portion of the antihelix 8 that extends to the helix 6 is the crus antihelicis superioris 16.
Each audio assembly 111 can include an earphone electronic assembly 210 that includes components to assist in providing audio to the user through the corresponding attached customizable ear insert 102. For example, each earphone electronic assembly 210 can include a memory 212, a processor 211 coupled to the memory 212, and a portable power source 216 (e.g., a battery) to power the components in the earphone electronic assembly 210. The memory 212 can include data (e.g., audio data) and one or more applications stored therein. The processor 211 may be any hardware unit or combination of hardware units capable of executing software applications and processing data, including, e.g., audio data. For example, processor 211 could be a central processing unit (CPU), a digital signal processor (DSP), an application-specific integrated circuit (ASIC), a combination of such units, and so forth. The processor 211 is configured to execute software applications, process audio data, and communicate with I/O devices among other operations.
The memory 212 may be any technically feasible type of hardware unit configured to store data. For example, memory 212 could be a hard disk, a random access memory (RAM) module, a flash memory unit, or a combination of different hardware units configured to store data. Software application(s) within memory 212 can include program code (e.g., instructions) that may be executed by processor 211 in order to perform various functionalities associated with the audio device, such as playing or adjusting audio output and/or activating the radiation source for curing the filler in the customizable ear insert 102 for a desired period of time.
The earphone electronic assembly 210 can further include I/O devices 213, such as a microphone assembly or a sensor (e.g., a pressure sensor), and an audio driver 214. The microphone assembly can be used to adjust the audio provided to the user based on feedback received at the microphone assembly, such as lowering the volume provided to the user when the user is speaking. For example, in one embodiment, the microphone assembly can include multiple microphones, such as a first microphone configured to receive a first audible signal from an external source (i.e., external to the audio device 100) and a second microphone configured to receive a second audible signal that is being provided to the user through the sound tube, thus enabling the audio device 100 to determine the relative difference between the two audible signals and then allow the audio device 100 to adjust the acoustic level of the second audible signal and/or improve the level of acoustic isolation experienced by the user. In one embodiment, the earphone electronic assembly 210 can include a plurality of pressure sensors at different locations within the earphone electronic assembly 210. The plurality of pressure sensors can be used to provide feedback to the user during the customization process to assist the user in applying a different pressure or a more uniform pressure at different portions of the earphone electronic assembly 210. Applying a more uniform pressure at different locations of the earphone electronic assembly 210 can help the user achieve a better result for customizing the ear inserts 102 to the user's ears. In some embodiments, one or more of the pressure sensors can alternatively be located within one of ear inserts 102, for example in the curable filler material disposed in the ear insert 102. The audio driver 214 is used to generate an audible output (e.g., one or more audio signals at frequencies >200 Hz) that is provided to the user of the audio device 100. Although only one audio driver 214 is shown, in some embodiments, each earphone electronic assembly 210 may include two or more audio drivers that can be used to produce the high-quality audio output commonly associated with some types of audio devices, such as in-ear monitors. In some embodiments, the audio driver 214 can be a balanced armature driver such that an electric current is passed through a coil that is wrapped around an armature. In other embodiments, the audio driver 214 can be a dynamic driver such that a diaphragm is attached directly to a voice coil that moves between one or more magnets.
The I/O devices 213 and the audio driver 214 can also be coupled to the processor 211 and to the memory 212. In some embodiments, each earphone electronic assembly 210 can include additional I/O devices (not shown) capable of receiving various inputs and/or providing various desirable outputs. These additional I/O devices may include one or more outputs (e.g., control relays) for controlling other outputs (e.g., radiation source 215 described below) of the earphone assembly 101. These I/O devices can also include one or more signal processing support components, signal filtering components (e.g., low pass and/or high pass filters) and components used to enable the delivery of an audible output from the audio driver 214 (e.g., signal amplifiers).
Each audio assembly 111 is attached to a corresponding customizable ear insert 102. In one embodiment, each customizable ear insert 102 includes a plurality of radiation sources 215. In some embodiments, the plurality of radiation sources can be embedded in the curable filler material disposed in the customizable ear insert 102. In other embodiments, one or more radiation sources 215 are disposed within the housing of the audio assembly 111 and adjacent to a surface of the customizable ear insert 102, as discussed further below in conjunction with
Each customizable ear insert 102 can further include a flexible printed circuit board (PCB) 217 and one or more supporting elements (see support spacer 402 in
The audio device 100 further includes the controller assembly 112, which is coupled to each earphone assembly 101 through the one or more cables 114 (see
The memory 202 may be any technically feasible type of hardware unit configured to store data. For example, memory 202 could be a hard disk, a random access memory (RAM) module, a flash memory unit, or a combination of different hardware units configured to store data. Software application(s) within memory 202 can include program code that may be executed by processor 205 in order to perform various functionalities associated with the audio device 100, such as playing or adjusting audio output and activating the radiation source 215 for curing the curable filler material disposed in the customizable ear insert 102 as well as communicating with external devices, such as the external electronic device 190 shown in
In an effort to avoid redundancy, in some embodiments of the audio device 100, the memory 202 and processor 205 may be the only processing components within the audio device 100, and thus multiple discrete processors and memory are not found within the audio device 100. In one configuration, any activities or processes that would have been performed by the processor(s) 211 and memory 212, if present in the audio assemblies 111, are performed by the use of the memory 202 and processor 205 of the controller assembly 112.
The controller assembly 112 can further include a transceiver 203 and I/O devices 204. In some embodiments, the transceiver 203 can be a wireless transceiver. The transceiver 203 can be configured to establish one or more different types of wireless communication links with other transceivers residing within other electronic devices, such as the external electronic device 190. For example, the transceiver 203 could establish a Wi-Fi communication link, a Bluetooth® communication link, or a near field communication (NFC) link, among other types of communication links with other electronic devices, such as the external electronic device 190. I/O devices 204 may include inputs (e.g., a 3.5 mm audio input jack) to receive audio input from an external wired audio source (not shown). I/O devices 204 may also include outputs and other inputs, such as one or more status indicators (e.g., LEDs) as well as buttons or switches to control and/or monitor the operation of the audio device 100 including starting and stopping audio playback as well as assisting in controlling and/or monitoring the curing process of the curable filler material disposed in the customizable ear insert 102.
The controller assembly 112 can further include a power controller 220. The power controller 220 can be used to control the supply of power from an external power source to the radiation sources 215 of the customizable ear insert 102 during the curing process. For example, the power controller 220 can be electrically coupled to an external power supply 301 through the connection assembly 113. The power controller 220 can be coupled to the radiation sources 215 through a power link 233 (e.g., a wired connection). The power controller 220 can be used to control the voltage and/or amperage supplied to the radiation sources 215 through the power link 233 during the curing process. In some embodiments, the power controller 220 can also be used to recharge the portable power sources 216 in the respective earphone assemblies 101 by use of the source power link 232. Furthermore, in some embodiments, a power controller can be located in each earphone assembly 101 instead of in the controller assembly 112.
The external power supply 301, introduced above, can be connected to the audio device 100. The external power supply 301 can include a portable power source 304 (e.g., a battery) and a power source connector 302. The portable power source 304 can generally supply substantially more power (e.g., Amp-hours) than the power sources within the audio device 100, such as the other portable power sources 206, 216 described above. The term portable power source as used herein generally describes a power source that is easily moveable and is able to provide power to electronic components in the audio device when the portable power source is not connected to a fixed power source, such as a wall electrical outlet or plug. The portable power source 304 can be used to supply the power to the radiation sources 215 during the curing process. The power source connector 302 can electrically couple the external power supply 301 to the connection assembly 113 (see also
The audio device 100 may communicate to the external electronic device 190 during use of the audio device 100 by the user. For example, the external electronic device 190 can be controlled by the user to control (e.g., initiate) and monitor the customization process performed on the audio device 100 to enable the earphones on the audio device 100 to be customized to the user's ear(s). The external electronic device 190 may also be used to stream audio content to the audio device 100 for listening by the user. The external electronic device 190 can communicate with the audio device 100 over the communication link 150, which can be a wireless communication link.
The external electronic device 190 can include a memory 196, a processor 195 coupled to the memory 196, and a power source 198 (e.g., a battery) to power the components in the external electronic device 190. The memory 196 can include data (e.g., audio data) and one or more applications stored therein. The memory 196 may be any technically feasible type of hardware unit configured to store data. For example, memory 196 could be a hard disk, a random access memory (RAM) module, a flash memory unit, or a combination of different hardware units configured to store data. Software application(s) within memory 196 can include program code that may be executed by processor 195 in order to perform various functionalities associated with the external electronic device 190, such as streaming audio content to the audio device 100 as well as providing a user interface for the user to control the customization of the ear inserts 102.
The processor 195 may be any hardware unit or combination of hardware units capable of executing software applications and processing data, including, e.g., audio data. For example, processor 195 could be a central processing unit (CPU), a digital signal processor (DSP), an application-specific integrated circuit (ASIC), a combination of such units, and so forth. The processor 195 is configured to execute software applications, process audio data, and communicate with I/O devices and to communicate to the controller assembly 112 of the audio device 100 among other operations.
The external electronic device 190 can further include a transceiver 193 for communicating with the controller assembly 112 of the audio device 100 through the communication link 150. The communication link 150 can also be used to stream audio content from the external electronic device 190 to the audio device 100 as well as for communication to the audio device 100 during the customizing of the ear inserts 102 to the user's ears. In some embodiments, the transceiver 193 can be a wireless transceiver. The transceiver 193 can be configured to establish one or more different types of wireless communication links with other transceivers residing within other electronic devices, such as the audio device 100. For example, the transceiver 193 could establish a Wi-Fi communication link, a Bluetooth® communication link, or a near field communication (NFC) link, among other types of communication links with other electronic devices, such as the audio device 100.
The external electronic device 190 can further include a speaker 197. The speaker 197 can be used for a number of operations including providing the user audio instructions and feedback before, during, and after the process for customizing the ear inserts 102 to the user's ears. The external electronic device 190 further includes the user interface introduced in
The external power supply 301 is shown disconnected from the audio device 100 to illustrate different features of the external power supply 301 and the connection assembly 113 of the audio device 100. The external power supply 301 can include a first cable 305 for connecting the portable power source 304 to the power source connector 302. The external power supply 301 can further include a second cable 306 (e.g., a USB cable) for connecting the portable power source 304 to an external power source for charging the portable power source 304.
The connection assembly 113 can include a plurality of connection terminals 113A for connecting to corresponding terminals (not shown) of the power source connector 302. The power source connector 302 can include a channel 309 for receiving the connection assembly 113. In some embodiments, one or more of the power source connector 302 and the connection assembly 113 can include magnetic material that is configured to be attracted to magnetizable material in the other connector to assist with creating and maintaining the electrical connection between the power source connector 302 and the connection assembly 113.
The customizable ear insert 102 further includes a sleeve assembly 401. The sleeve assembly 401 forms an enclosure to house components within the customizable ear insert 102, such as the curable filler material, the flexible PCB 217 and the radiation sources 215. The sleeve assembly 401 can include a flexible and deformable material that can conform to the shape of the user's ear during curing process. The sleeve assembly 401 includes a collar 411 (
The sleeve assembly 401 can include a “sleeve body” that includes a sleeve 600 (see
The sleeve 600 (see
The customizable ear insert 102 further includes a sound tube assembly 403. The sound tube assembly 403 includes a sound tube 422. The sound tube 422 includes an input region 425 and an output region 426. The input region 425 is disposed at the input end of the sound tube 422 and adjacent to the opening formed in the protrusion 111A. The sound tube 422 is used to transfer the audio output provided from the audio driver 214 to the user. The audio output from the audio driver 214 is received at the input region 425 of the sound tube 422 and then transferred through the sound tube to the output region 426 of sound tube 422 and to the user through the ear tip 412 of the sleeve assembly 401.
The sound tube assembly 403 further includes a base 421. The base 421 of the sound tube assembly 403 can be used to retain the sound tube assembly 403 within the sleeve assembly 401. For example, the base 421 of the sound tube assembly 403 can contact and be supported by the interior of the collar 411 of the sleeve assembly 401 as shown in
The customizable ear insert 102 further includes a support 404 disposed between the collar 411 of the sleeve assembly 401 and the audio assembly 111. The support 404 can be formed from a more rigid material than the sleeve assembly 401 to provide structural support for the customizable ear insert 102. The base 421 of the sound tube assembly 403 can also be connected to the support 404. For example, in one embodiment the support 404 is connected to the base 421 (
The flexible PCB 217 can be positioned between the base 421 of the sound tube assembly 403 and the output region 426 of the sound tube assembly 403. In some embodiments, the flexible PCB 217 can have a shape of a ring or a partial ring, so that the flexible PCB 217 at least partially surrounds the sound tube 422. A plurality of radiation sources 215, such as LED's, can be disposed on the flexible PCB 217. Having the plurality of radiation sources 215 disposed on the flexible PCB 217 (i.e., opposed to a non-flexible PCB) that is disposed around the sound tube 422 can help prevent the user from feeling the presence of the PCB during use of the audio device 100 while also reducing the likelihood that a rigid portion of a non-flexible PCB could puncture the sleeve assembly 401. The flexible PCB 217 can further include a larger than normal copper ground plane to serve as a heat sink to remove the heat generated by the radiation sources 215 during the customization process and deliver it to the thermally conductive components in the audio assembly. In some embodiments, a current from about 50 mA to about 150 mA, such as about 100 mA, can be provided to the radiation sources 215 during the customization process. In some embodiments, the flexible PCB 217 or the power controller 220 (see
The plurality of radiation sources 215 can be spaced apart from each other around the flexible PCB 217 to reduce a furthest distance between the radiation sources 215 and portions of the curable filler material disposed in the sleeve assembly 401, such as portions of the curable filler material disposed in the ear tip 412 of the sleeve assembly 401. In one embodiment, each radiation source 215 can have a particularly small footprint inside the sleeve assembly 401, such as about 1.6 mm by about 1.6 mm. In some embodiments, a support spacer 402 can be positioned between the base 421 of the sound tube assembly 403 and the flexible PCB 217 to allow further precision for positioning the radiation sources 215 inside the sleeve assembly 401. In some embodiments, the flexible PCB 217 can be connected to the sound tube assembly 403, for example, by using fasteners that connect to the base 421 of the sound tube assembly 403.
In some embodiments, the sleeve body of the sleeve assembly 401 includes a sleeve 600 and an interior coating 601. In one configuration, the sleeve 600 can be formed from materials, such as silicone, fluorosilicone, nitrile, acrylate, high consistency rubber (HCR), and thermoplastic elastomers (e.g., thermoplastic polyurethane (TPU), such as aliphatic TPU). The interior coating 601 can have a thickness from about 50 μm to about 200 μm, such as about 100 μm. In one embodiment, the interior coating 601 can be formed from a silicone material that includes a reflective material, such as titanium dioxide, silver, or aluminum oxide. In one example, the interior coating 601 includes titanium dioxide having a grain size from about 100 nm to about 200 nm, such as about 150 nm. In some embodiments, the interior coating 601 can be evaporated onto, painted onto, sputtered onto, printed onto or sprayed onto the sleeve 600. The interior coating 601 can be used to form a barrier and/or reflective surface that reflects the energy emitted from the radiation sources 215. For example, in one embodiment, the radiation sources 215 emit radiation at a wavelength of about 405 nm, and the interior coating 601 is configured to reflect substantially all radiation having a wavelength of 405 nm, such as a material having a reflectance greater than 95% for radiation having a wavelength of 405 nm, such as a material having a reflectance greater than 99% for radiation having a wavelength of 405 nm.
Although the sleeve body of the sleeve assembly 401 is largely described herein as including a reflective interior coating, in some embodiments, the material used to form the sleeve 600 can be reflective, such as a polymer embedded with a reflective material, such as a silicone sleeve having titanium dioxide embedded in the silicone. In some embodiments, the sleeve body includes a sleeve 600 that contains a reflective material within it, and also does not include an interior coating 601. However, in embodiments in which the material used to form the sleeve 600 is reflective to the radiation from the radiation sources 215, an interior coating 601 may still be included within the sleeve body. In such embodiments, the interior coating can serve as a barrier to prevent migration of the curable filler material into or through the sleeve 600 while also being transparent to the radiation from the radiation sources 215, so that the radiation can be reflected by the material found within the sleeve 600.
The sound tube assembly 403 is disposed inside the sleeve assembly 401 and includes the sound tube 422. The sound tube 422 extends from the input region 425 of the sound tube 422 to the output region 426 of the sound tube 422 to transmit sound received from the audio driver 214 at the input region 425 to the user through the output region 426 of the sound tube 422. An inner volume 610 is located in the empty space between the sleeve assembly 401 and the components inside the sleeve assembly 401, such as the sound tube assembly 403. The curable filler material, which is used for customizing the ear insert 102 to the user's ear, can be added to the inner volume 610 during the manufacturing process.
The sleeve assembly 401 can further include an inward protrusion 622 formed over the sound tube 422 at the output region 426 of the sound tube 422. The inward protrusion 622 can surround a portion of the length of the sound tube 422 without blocking the output region 426 of the sound tube 422. The customizable ear insert 102 can further include a clasp 615 to assist in holding the inward protrusion 622 to the sound tube 422. The inward protrusion 622 can include a notch 623 for receiving the clasp 615. The notch 623 can help prevent the clasp 615 from moving after securing the inward protrusion 622 to the sound tube 422. In one embodiment, the clasp 615 can be an elastic ring. In other embodiments, the clasp 615 can be omitted, and the sound tube 422 at the output region 426 can be secured to a portion of the sleeve assembly 401 (i.e., a portion that is the same or similar to the inward protrusion 622) by welding or other methods.
The sound tube assembly 403 can further include an outer coating 602. The outer coating 602 can form a reflective surface that reflects the energy emitted from the radiation sources 215. In one embodiment, the outer coating 602 of the sound tube assembly 403 can be formed from the same material as the interior coating 601 of the sleeve assembly 401, such as silicone having a reflective material (e.g., titanium dioxide) embedded in the silicone. Furthermore, in some embodiments, all surfaces inside the sleeve assembly 401 that can be exposed to the radiation from the radiation sources 215 can be coated with the reflective material which is configured to reflect the energy emitted from the radiation sources 215, such as the same material used for the interior coating 601 of the sleeve assembly 401. In other embodiments, the sound tube 422 and other components inside the sleeve assembly 401 can be formed of a reflective material, such as a polymer that is loaded with an amount of a reflective material, such as a silicone material having titanium dioxide embedded in the silicone.
The support spacer 402 is disposed over the base 421 of the sound tube assembly 403. The flexible PCB 217 is disposed over the support spacer 402. The plurality of radiation sources 215 are disposed on the flexible PCB 217. As noted above, in some embodiments, the connectors 405 are used to attach the customizable ear insert 102 to the audio assembly 111. The connectors 405 can be attached to a component of the customizable ear insert 102 during manufacturing, such as being fastened to the support 404. A portion of each connector 405 can extend into or completely through the support 404 as part of providing an electrical connection to the radiation sources 215. The connectors 405 can receive electrical power from the power link 233 when the customizable ear insert 102 is connected to the audio assembly 111. The power link 233 can receive electrical power from the external power supply 301 as shown in
The audio assembly 111 also includes a housing that includes an outer housing 111B and a lid 111C. In some embodiments of the housing, the lid 111C includes the protrusion 111A that has an opening that allows sound provided from the one or more audio drivers 214 to be injected into the input region 425 of the sound tube 422. The outer housing 111B and lid 111C are configured to support and enclose the components found within the earphone electronic assembly 210 discussed above, which will include components that at least assist in providing audio to the user through the corresponding attached customizable ear insert 102 (e.g., audio driver 214).
The curable filler material 801 can be formed of a material that is biocompatible in both the uncured and cured state, so that potential contact with a user's skin does not irritate or harm the user. In embodiments, in which the curable filler material 801 is a photopolymer, the curable filler material 801 can include a concentration of photoinitiator to allow the curable filler material 801 to cure in about 30 seconds to about 120 seconds, such as curing in about 60 seconds. In some embodiments, the curable filler material 801 includes a polymer material, such as a silicone material. In some embodiments, the curable filler material 801 includes a fluoropolymer material, such as a fluorinated silicone material. In one embodiment, the curable filler material 801 includes fumed silica to enhance the mechanical properties of the curable filler material 801. The curable filler material 801 can have a viscosity before curing from about 15,000 cP to about 1,000,000 cP, such as from about 50,000 cP to about 120,000 cP, such as about 80,000 cP. In some embodiments, the curable filler material 801 can have a hardness after curing that is from about 20 Shore A scale to about 50 Shore A scale, such as about 30 Shore A after a curing process has been performed. In some embodiments, the curable filler material 801 can cure in about 30 seconds to about 120 seconds, such as in about 60 seconds. Furthermore, the curable filler material 801 and the sleeve assembly 401 can each remain flexible after curing, which also allows the combination of the curable filler material 801 and the sleeve assembly 401 to remain flexible. Typically, customized earpieces are rigid and non-flexible after customization is performed, which can present numerous problems for the user. For example, as a user ages, gains or loses weight, small but still significant changes to the contours of the user's ears can occur. These small changes to the user's ears can cause users of typical rigid and non-flexible customized earpieces to experience a fit, comfort, and performance that deteriorates over time. On the other hand, in the present disclosure, by maintaining flexibility of the curable filler material 801 and the sleeve assembly 401, the user can enjoy a consistent fit, comfort, and performance during use the flexible customizable ear inserts 102 that can adjust to the small changes in the contours of the user's ears that can occur over time. Furthermore, having the customizable ear inserts 102 maintain flexibility after curing also prevents the ear inserts 102 from being abrasive or otherwise injuring or irritating users as the users insert and remove the ear inserts 102 from the user's ears.
In some embodiments, the curable filler material 801 is selected so that it bonds with the material used to form the interior coating 601, and/or material used to form the sleeve 600, to prevent relative motion between the sleeve assembly 401 and the cured curable filler material 801 during normal use by a user. Relative motion between the sleeve assembly 401 and the cured curable filler material 801 can lead to the material in the sleeve assembly 401 “bunching-up” in certain regions of the customizable ear insert 102 when a load is applied to the customizable ear insert 102 during its insertion into the user's ear or other normal use, which can make the customizable ear insert 102 uncomfortable for the user to wear. The bond formed between the curable filler material 801 and the interior coating 601, and/or material used to form the sleeve 600 of the sleeve body, can be desirably controlled by the selection of compatible materials that will allow molecular scale mixing, chain entanglement and/or chemical bonding at the interface between cured curable filler material 801 and the interior coating 601 and/or material used to form the sleeve 600. In one example, the curable filler material 801 and the interior coating 601, and/or material used to form the sleeve 600, each include a silicone material. Another consideration when selecting the curable filler material 801 and materials for the sleeve assembly 401 is preventing migration of the curable filler material 801 through the sleeve body of the sleeve assembly 401 in an uncured state. It has been found that selecting compatible yet still flexible materials for the sleeve assembly 401 and curable filler material 801 is important to prevent migration of uncured or cured filler material 801 into or through the sleeve assembly 401. The materials for the curable filler material 801 and the sleeve assembly 401 can be selected to ensure a shelf life of at least six months. In some embodiments, the customizable ear inserts 102 can be vacuum sealed for packaging, placed inside an opaque package, and/or maintained in a controlled environment prior to customer use to enhance the shelf life of the customizable ear inserts 102. In some embodiments, including fluorosilicone in the sleeve assembly 401, such as part of the sleeve 600 or the interior coating 601, can prevent migration of the curable filler materials 801 described above.
Referring to
At block 2004, the audio device 100 can be paired (e.g., a Bluetooth® pairing process) with the external electronic device 190 (see
At block 2006, the external power supply 301 can be attached to the connection assembly 113 of the audio device 100 (see
At block 2008, the user can select and attach customizable ear inserts 102 to corresponding audio assemblies 111 (see
At block 2010, the user can insert the customizable ear inserts 102 of the audio device 100 into the user's ears. For example, the user can insert the ear tips 412 (see
At block 2014, the user can press a start button in a software application running on the external electronic device 190 to initiate the customization process to cure the curable filler material 801 (see
At block 2016, the user can press against the audio assemblies 111 urging the customizable ear inserts 102 towards the user's ears so that the curable filler material 801 and sleeve assembly 401 can deform and conform to the shape of the user's ears. Also, at block 2016, the actual curing process begins as power is supplied to the radiation sources 215 of the customizable ear inserts 102 (see
During the processes performed at block 2016, the temperature of the curable filler material 801 may be monitored by use of a temperature sensing device (not shown) found in the I/O devices 213 found within the earphone electronic assembly 210. If the measured temperature is out of a desired range (i.e., too high or too low) a warning can be supplied to the user in the form of an audible signal or a prompt displayed on the external electronic device 190.
During the processes performed at block 2016, the pressure applied to the curable filler material 801 by the user may be monitored by use of a pressure sensing device (not shown) (e.g., strain gauge) found in the I/O devices 213 found within the earphone electronic assembly 210. If the measured pressure applied by the user is out of a desired range (i.e., too high or too low) a warning can be supplied to the user in the form of an audible signal or a prompt displayed on the external electronic device 190.
The first flat tube 941 can be used to add the curable filler material 801 to the inner volume 610 of the sleeve assembly 401. The second flat tube 942 can be used to apply suction to the inner volume 610 of the sleeve assembly through the second flat tube 942 to assist in distributing the curable filler material 801 throughout the inner volume 610 of the sleeve assembly 401. The sound tube assembly 403, the support spacer 402, and the flexible PCB 217 can be formed of flexible, compressible materials that can allow the flat tubes 941, 942 to be expanded when the curable filler material 801 is added through the first flat tube 941 and the suction is applied to the inner volume 610 through the second flat tube 942. In one embodiment, balloon catheters can be used to expand the flat tubes 941, 942 during addition of the curable filler material 801 to the inner volume 610.
Referring to
At block 3006, the sound tube assembly 403 can be formed. The sound tube assembly 403 can be formed using various molding processes, such as compression molding, injection molding, and dip molding. At block 3008, the sound tube assembly 403 can optionally be coated with the reflective outer coating 602. In some embodiments, the sound tube 422 may include a reflective material, and thus the reflective outer coating 602 can be omitted.
At block 3010, the support spacer 402 and the flexible PCB 217 can be attached to the base 421 of the sound tube assembly 403, for example by using fasteners. At block 3012, the sound tube assembly 403 can be attached to the sleeve assembly 401. For example, in one embodiment the clasp 615 can be used to secure the sound tube 422 to the inward protrusion 622 of the sleeve assembly 401.
In an alternative embodiment, the sound tube assembly 403 can be formed first using the molding process described for block 3006, and then the sleeve assembly 401 can be overmolded onto the sound tube assembly 403. For example, in one embodiment, the sleeve assembly 401 can overmolded onto the sound tube assembly 403, so that the sleeve assembly 401 is formed inside out and the sleeve assembly 401 is attached to the sound tube assembly 403 near the end of the sound tube 422, for example around the area where the clasp 615 is shown in
At block 3014, the sleeve assembly 401 is turned outside out and stretched around the base 421 of the sound tube assembly 403, so that the tubes 423 of the sound tube assembly 403 can extend through the collar 411 of the sleeve assembly 401. At block 3016, the support 404 can be attached to the sound tube assembly 403, for example by using a fastener that extends through the support 404, the collar 411 of the sleeve assembly 401 and into the base 421 of the sound tube assembly 403.
At block 3018, the curable filler material 801 can be added to the inner volume 610 of the sleeve assembly 401. For the customizable ear insert 102 (see
In one embodiment, for an alternate configuration of the customizable ear insert 103 (see
The customizable ear insert 1102 includes one or more radiation sources 215 that are not connected to a fiber optic cable. These radiation sources 215 emit light into the curable filler material from some of the same locations described above for the customizable ear insert 1102, which is near the base 421 of the sound tube assembly 403. Furthermore, although only one fiber optic cable 1105 is shown in
In some embodiments, the fiber optic cable 1205 can connect to an external LED 1210. A fiber optic cable 1211 can transmit light from the external LED to the fiber optic cable 1205 that transmits the light to the curable filler material 801 in the sleeve assembly 401. A fiber optic coupling 1215 can be used to couple the fiber optic cable 1211 to the fiber optic cable 1205. The fiber optic cable 1205 can serve to promote a fuller cure of the curable filler material in the ear tip 412 and to balance the cure rate of the curable filler material 801 in the ear tip 412 with the curable filler material 801 in other locations in the sleeve assembly 401 in a similar manner as described above in reference to
In some embodiments in which an external LED is used to transmit light into the sleeve assembly 401 with a fiber optic cable, the radiation sources 215, the flexible PCB 217, and the support spacer 402 can be omitted. In some of these embodiments, more than one fiber optic cable or a fiber optic cable with multiple branches can be used to transmit light to different locations inside the sleeve assembly 401 to balance the cure rate of the curable filler material 801 in the different locations with each other to reduce the mechanical stresses caused by cure rate variability as described above in reference to
The sound tube 1320 can include a first portion 1321 and a second portion 1322 that are not coated by the outer coating 602. The first portion 1321 can be located near one of the radiation sources 215. The second portion 1322 can be located in the ear tip 412 of the sleeve assembly 401. Light L from the radiation source 215 near the first portion 1321 can be transmitted into the sound tube 1320, and this light L can then be transmitted out of the sound tube 1320 at the second portion 1322 to the curable filler material (not shown) located in the ear tip 412. In some embodiments, an opaque reflective cap 1330 can be placed over the ear tip 412, so that the light L in the sound tube 1320 is not directed at the user. This opaque, reflective cap 1330 can be especially important if the radiation sources 215 emit UV energy since exposure to UV energy should be avoided. The fiber optic cable 1205 can include an end 1207 positioned in the ear tip 412 of the customizable ear insert 1202 for emitting light directly into curable filler material 801 located in the ear tip 412. Emitting light into the curable filler material 801 in ear tip 412 through the second portion 1322 of the sound tube 1320 can increase the cure rate of the curable filler material 801 located in the ear tip 412 and can also promote a fuller cure of the curable filler material 801 located in the ear tip 412 when compared to the customizable ear insert 102 that only emits light from the radiation sources 215 into the curable filler material 801 located near the base 421 of the sound tube assembly 403.
In another embodiment, a sound tube assembly that includes variations in transparency can be used to further balance the distribution of light to the curable filler material during the customization process. For example, in one embodiment, a transparent sound tube assembly can be formed, and then different portions of the sound tube can be coated with varying amounts of an opaque or semi-transparent coating so that the transparency of the sound tube gradually varies along the length of the sound tube. The sound tube assembly may still include a more fully transparent portion adjacent to the radiation source 215 similar to the first portion 1321 described above. In one such embodiment, the transparency of the sound tube (excluding the more fully transparent portion near the radiation source 215) can gradually increase as the sound tube extends towards the ear tip 412. The ear tip 412 may also include a more fully transparent portion similar to the second portion 1322 described above. A gradual variance in the transparency of the sound tube can help to balance the light emitted upon different portions of the curable filler material, so that the cure rate of the different portions can be more uniform.
During the manufacturing process, in one embodiment, the curable filler material 801 is injected into the ear tip portion 412 using a filling device 1410 that includes a tube 1401 that is coupled to a curable filler material source 1405. Before injection, the curable filler material 801 is contained within the curable filler material source 1405 that is fluidly coupled to the tube 1401. Thereafter, the tube 1401 is inserted through the ear tip portion 412 of the ear insert 102. Due to pressure applied to the curable filler material 801 from a pressure controlling device (e.g., gas source, manual user compressible component) in the curable filler material source 1405, the curable filler material 801 will flow through the tube 1401 and into the area of the inner volume 610 where the tube 1401 is inserted. In some embodiments, the tube 1401 can have a valve 1407 and actuator 1408. The valve 1407 can be used to selectively apply the curable filler material 801 into the inner volume 610 from the curable filler material source 1405, and, alternatively, the actuator 1408 can be used to pull air out of the inner volume 610, by a pumping action.
Additionally, in some embodiments, shields 1430A (
In other embodiments, as shown in
Thereafter, the curable filler material 801 can be inserted by the curable filler material source 1405 into the inner volume 610 through a space 1470 formed near the ear tip 412 without having to insert the tube 1401 through the sleeve assembly 401. After insertion of the curable filler material 801 within the inner volume 610, the inward protrusion 622 of the sleeve assembly 401 can be folded from its open position (i.e.,
In another embodiment, as shown in
In some embodiments, the LEDs are positioned to output light (L shown in
Also shown in
In other embodiments, the sleeve assembly 401 is configured to include different thicknesses in different regions of the sleeve 600 of the sleeve body. The control of different thickness of the sleeve 600 can also help prevent or eliminate collapsing of the sleeve assembly 401 during its insertion into the user's ear. For example, as shown in
In some embodiments, referring to
While the foregoing is directed to embodiments of the present disclosure, other and further embodiments of the disclosure may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.
This application claims the benefit of U.S. provisional patent application Ser. No. 62/613,397, filed Jan. 3, 2018, which is herein incorporated by reference.
Number | Date | Country | |
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62613397 | Jan 2018 | US |