Patent Application
20090304981
(1) FIELD OF THE INVENTION
The present invention relates to a flexible coat for an ear bud and a smooth outer layer is securely coated to the outside of the coat. A method for making the coat is disclosed.
(2) DESCRIPTION OF THE PRIOR ART
A conventional coat for an ear bud generally is made by flexible silicone material which cannot provide satisfied flexibility so that when inserting the ear bud into the user's the external auditory canal, the silicone coat may not fit with the shape of the external auditory canal and makes the user feel uncomfortable. Besides, because the coat on the ear bud does not fit with the external auditory canal, gap is defined between the external auditory canal and the coat of the ear bud so that the noise from outside of the ear interrupts the music and the ear bud is easily to loose from the user's ear.
The latest coat for ear buds is made by foam material which is more flexible than the silicone and can fit with the user's the external auditory canal. However, the foam material basically is a porous material and cannot be shaped in a mold set to have a desired shape. Besides, the porous material easily traps dust or even earwax therein which are difficult to be cleaned out from the porous coat.
Some manufacturers develop an outer layer attached to the porous coat so as to prevent the dust and/or earwax from being trapped in the porous coat. However, the outer layer is easily peeled off from the coat and may impede the sound when passing through the outer layer.
The present invention intends to provide a coat for ear buds and the coat is flexible and shaped to fit with the user's the external auditory canal. A smooth outer layer is securely attached with the coat and hides the pores of the coat from dust and/or earwax.
The present invention relates to a method for making a coat for ear buds, the method comprises the following steps:
a step of preparing a mold set comprising a male mold and a female mold, the male mold having insertions extending therefrom and the female mold having concavities, spreading a layer of non-foam Polyurethane material to outside of the insertions and an inside of the concavities;
a step of filling foam material in the concavities;
a step of matching the male and female molds to insert the insertions into the concavities, foaming the foam material, and
a step of separating the male and female molds to pick up coats with the non-foam Polyurethane layer coated thereon.
The present invention further discloses a coat for ear buds and the coat includes a body having pre-set shape and a layer of non-foam Polyurethane material is attached to outside of the body. The body is a bullet-shaped member and includes a flat portion and a curved portion. A recess is defined in the flat portion and a path is axially defined through the body and communicates with the recess. The path forms an opening through of the curved portion. The layer of non-foam Polyurethane material is coated on outside of the flat portion, the curved portion, an inside of the recess and an inside of the path.
The present invention will become more obvious from the following description when taken in connection with the accompanying drawings which show, for purposes of illustration only, a preferred embodiment in accordance with the present invention.
Referring to
A step of preparing a mold set comprising a male mold 30 and a female mold 40. The male mold 30 has insertions 31 extending therefrom and the female mold 40 have concavities 41. A layer of non-foam Polyurethane material 20 is spread to outside of the insertions 31 and an inside of the concavities 41.
The insertions 31 each are stepped protrusions and a protrusion 42 extends from a center of the inside of each of the concavities 41. A depth of each of the concavities 41 is deeper than a length of the insertion 31 corresponding thereto.
A step of filling Polyurethane foam material “A” in the concavities 41.
A step of matching the male and female molds 30, 40 to insert the insertions 31 into the concavities 41, and then heating and pressing the mold set to foam the Polyurethane foam material “A”. A gap is defined between an end of the insertion 31 and a top of the protrusion 42 when the male and female molds 30, 40 are matched with each other.
A step of separating the male and female molds 30, 40 to pick up coats 1 with the layer of non-foam Polyurethane material 20 coated thereon. The non-foam Polyurethane layer 20 hides the pores of the Polyurethane foam material and includes a smooth outer surface so as to prevent dust and/or earwax from being trapped in the pores. It is noted that the layer of non-foam Polyurethane material 20 is Polyurethanes which does not become yellow after being used.
As shown in
As shown in
The membrane 25 is formed in the gap defined between the end of the insertion 31 and the top of the protrusion 42 when the male and female molds 30, 40 are matched with each other, the membrane 25 is thin and sound can easily pass through the membrane so that the quality is not affected. Besides, the membrane 25 may resonate with the music so that even if the music is weak, the user can enjoy the music.
While we have shown and described the embodiment in accordance with the present invention, it should be clear to those skilled in the art that further embodiments may be made without departing from the scope of the present invention.
