Apparatus and method for forming custom earpieces

Abstract

Embodiments of the present disclosure relate generally to custom-fit in-ear audio devices, also referred to herein as in-ear audio devices, custom-fit earpieces, or simply earpieces. Embodiments of custom-fit earpieces that provide superior retention in a user's ear while also maintaining desirable comfort and sound quality are disclosed below. Superior retention is provided by a curable filler material that is generally disposed in a sleeve body, which deforms to conform to the shape of a user's ear when the curable filler material is cured. The comfort level of the custom-fit earpieces described herein is enhanced because the audio output member is able to move independently or relative to the portion of the earpiece that contains the curable filler material, thereby allowing the audio output member to adapt to and comfortably fit within a given user's ear canal.

Description

[0001] This application is a divisional application of Chinese patent application filed on January 2, 2019, with application number 2019800170785 and invention title "Apparatus and Method for Forming Custom Headphones". Technical Field

[0002] Embodiments of this disclosure generally relate to custom-made headphones and methods for customizing headphones for use in a user's ear. Background Technology

[0003] Audio devices allow users to receive audio content or information from various media sources, such as the internet, video players, gaming devices, music streaming platforms, or other types of audio-generating devices. Typical portable in-ear audio devices can 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 hardwired or wirelessly connected to an audio source to listen to the audio provided to the device.

[0004] Typically, it is preferred to customize the shape of in-ear audio devices to fit the user's ear, ensuring comfortable wear, easy retention in the ear, and the ability to eliminate or control ambient noise when inserted. Traditionally, custom-made in-ear audio devices have used a wax molding process to fine-tune the device to the unique shape of the user's ear. While this wax molding process allows for a well-fitting custom in-ear audio device, it can be time-consuming and expensive. This process may require the user to travel to a location where wax molding of the user's ear can be performed. The user must then wait several days until the custom in-ear audio device can be produced based on the wax molding and then shipped to the user.

[0005] Therefore, there is a need for improved, tailored in-ear audio devices and methods for customizing in-ear audio devices that overcome the shortcomings described above. Summary of the Invention

[0006] Embodiments of this disclosure may provide an audio device including an audio assembly comprising an audio speaker and an earpiece connected to the audio assembly. The earpiece may include a housing, one or more light sources disposed within the housing, a sound tube disposed within the housing, wherein the output of the audio speaker is connected to the input of the sound tube, and a curable filler material disposed within the housing and surrounding the sound tube, wherein the one or more light sources are disposed within the curable filler material.

[0007] Embodiments of this disclosure may provide an audio device including an audio assembly comprising an audio speaker and an earpiece connected to the audio assembly. The earpiece may include a housing, a light-reflective coating disposed on an inner surface of the housing, a sound tube disposed within the housing, wherein the output of the audio speaker is connected to the input of the sound tube, and a curable filler material disposed within the housing and surrounding the sound tube, wherein one or more light sources are disposed outside the curable filler material and adjacent to a surface of the housing excluding a portion of the light-reflective coating.

[0008] Embodiments of this disclosure may also provide an audio device, including an audio component comprising an audio speaker and an earpiece connected to the audio component. The earpiece may include a sleeve covered by a first reflective material, one or more light sources disposed within the sleeve, a sound tube disposed within the sleeve, wherein the sound tube is covered by a second reflective material and the output of the audio speaker is connected to the input of the sound tube, and a curable filler material disposed within the sleeve and surrounding the sound tube.

[0009] Embodiments of this disclosure may provide an audio device including an audio assembly comprising an audio speaker and an earpiece connected to the audio assembly. The earpiece may include a housing having an ear tip having an output portion for directing audio to a user, a first light source, a sound tube disposed within the housing, wherein the output portion of the audio speaker is connected to an input portion of the sound tube, a curable filler material disposed within the housing and surrounding the sound tube, and an optical fiber cable extending from one of the first light sources to an internal portion of the ear tip of the housing.

[0010] Embodiments of this disclosure may provide an audio device including an audio assembly comprising an audio speaker and an earpiece connected to the audio assembly. The earpiece may include a housing having an ear tip having an output portion for directing audio to a 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 portion of a sound tube, wherein the sound tube assembly is disposed within the housing, the output portion of the audio speaker is connected to an input portion 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 each of the first and second portions is optically more translucent than the second portion and the second portion is disposed between the first and third portions, and a curable filler material disposed within the housing and surrounding the sound tube.

[0011] Embodiments of this disclosure may provide a method for forming a customizable earplug, including forming a sound tube, overlapping and molding a sleeve body onto the sound tube, inserting the sound tube into the sleeve body by flipping the sleeve body from the inside out, and adding a curable filler material into the interior of the sleeve body.

[0012] Embodiments of this disclosure may provide a method for forming a customizable earplug, comprising inserting a sound tube into the internal volume of a flexible housing, wherein the flexible housing includes a portion for providing audio to the user's ear tip and a collar for holding the sound tube in the internal volume, inserting a first flat tube through the collar of the flexible housing to connect the internal volume of the flexible housing to the external environment, expanding the first flat tube using a first conduit, and adding a curable filler material through the first conduit to the internal volume of the flexible housing.

[0013] Embodiments of this disclosure may also provide an audio device including two in-ear headphone assemblies, each of the two in-ear headphone assemblies including an earbud and an audio component. Each of the earbuds in the two in-ear headphone assemblies includes a housing having an inner surface and including an elastic material and a reflective material configured to reflect light of one or more wavelengths emitted by a radiation source, a sound tube coupled to the housing, wherein the inner surface of the housing and the outer surface of the sound tube at least partially define an internal volume of the earbud, and a curable filler material disposed within the internal volume, wherein the curable filler material is configured to be cured by light of one or more wavelengths emitted by the radiation source. Each of the audio components in the two in-ear headphone assemblies includes an audio driver configured to transmit audible sound to the inner surface of the sound tube. The outer surface of the housing of the earbud in the first of the two in-ear headphone assemblies has a shape different from the shape of the outer surface of the housing of the earbud in the second of the two in-ear headphone assemblies.

[0014] Embodiments of this disclosure may also provide an audio device including an earbud-type headphone assembly. The earbud-type headphone assembly includes an earbud and an audio component. The earbud includes a housing having an inner surface and includes an elastic material and a reflective material configured to reflect light of one or more wavelengths emitted by a radiation source, a sound tube coupled to the housing, wherein the inner surface of the housing and the outer surface of the sound tube at least partially define an internal volume of the earbud, and a curable filler material disposed within the internal volume, wherein the curable filler material is configured to be cured by light of one or more wavelengths emitted by a radiation source. The audio component includes an audio driver configured to transmit audible sound to the inner surface of the sound tube. The audio component may be detachably coupled to the earbud. Attached Figure Description

[0015] Therefore, in a manner that allows for a detailed understanding of the features described above in this disclosure, a more specific description of the disclosure, which has been briefly outlined above, can be made with reference to embodiments, some of which are illustrated in the accompanying drawings. However, it will be noted that the accompanying drawings illustrate only exemplary embodiments and are therefore not to be considered as limiting their scope, and other equally effective embodiments may be permitted.

[0016] Figure 1A This is a perspective view of an audio device customization system according to one implementation method;

[0017] Figure 1B This is an exemplary illustration of the human external ear;

[0018] Figure 1C This is a perspective view of an earbud-type headphone assembly arranged within a portion of the ear after a user-customized earpiece has been made to conform to the shape of the user's ear, according to one embodiment.

[0019] Figure 2 According to one implementation method Figure 1A The diagram shown is a block diagram of an audio device customization system.

[0020] Figure 3 It is a perspective view of an audio device and an external power supply according to one embodiment;

[0021] Figure 4 It is a perspective view of an earphone assembly of an audio device according to one embodiment, including an exploded view of a customizable earbud.

[0022] Figure 5 This is a perspective view of an earbud-type headphone assembly according to one embodiment;

[0023] Figure 6 It is according to one implementation method along Figure 5 A cross-sectional view of an earbud headphone assembly taken from section line 6-6;

[0024] Figure 7 The illustration shows a cross-sectional view of a customizable earplug after a curable filler material has been added to it, according to one embodiment.

[0025] Figure 8 This is a process flow diagram of a method for customizing an audio device for a user's ear according to one embodiment.

[0026] Figure 9A The illustration shows a cross-sectional view of a customizable earplug according to one embodiment and certain components for adding curable filler material to the customizable earplug.

[0027] Figure 9B The illustration shows a cross-sectional view of a customizable earplug according to one embodiment and certain components for adding curable filler material to the customizable earplug.

[0028] Figure 9C The illustration shows an implementation method that has been used for expansion. Figure 9BThe first flattened balloon catheter;

[0029] Figure 10 This is a process flow diagram for manufacturing customizable ear tips and methods for manufacturing customizable ear tips;

[0030] Figure 11 The illustration shows a cross-sectional view of a customizable earplug after a curable filler material has been added to it, according to one embodiment.

[0031] Figure 12 The illustration shows a cross-sectional view of a customizable earplug after a curable filler material has been added to it, according to one embodiment.

[0032] Figure 13 The illustration shows a cross-sectional view of a customizable earbud according to one embodiment before a curable filler material has been added to the customizable earbud.

[0033] Figure 14A It is a cross-sectional view of a customizable earplug before the curable filler material has been added to the customizable earplug, according to at least one embodiment.

[0034] Figure 14B It is based on at least one embodiment in Figure 14A The illustration shows a close-up cross-sectional view of a portion of the customizable earbuds.

[0035] Figure 14C It is based on at least one embodiment in Figure 14A The illustration shows a close-up cross-sectional view of a portion of the customizable earbuds.

[0036] Figure 14D It is based on at least one embodiment in Figure 14A The illustration shows a close-up cross-sectional view of a portion of the customizable earbuds.

[0037] Figure 14E It is a cross-sectional view of a customizable earplug before the curable filler material has been added to the customizable earplug, according to at least one embodiment.

[0038] Figure 15A It is a cross-sectional view of a customizable earplug after a curable filler material has been added to the customizable earplug, according to at least one embodiment.

[0039] Figure 15B It is based on at least one embodiment in Figure 15A The image shows a close-up cross-sectional view of a portion of the customizable earbuds.

[0040] Figure 16It is a cross-sectional view of a customizable earplug before the curable filler material has been added to the customizable earplug, according to at least one embodiment; and

[0041] Figure 17 It is according to at least one embodiment along in Figure 6 The cross-sectional view of the customizable earbuds shown is taken from the cross-section line.

[0042] To aid understanding, the same reference numerals have been used (where possible) to designate the same elements generally applicable to the drawings. It is contemplated that elements and features of one embodiment may be advantageously combined in other embodiments without further description. Detailed Implementation

[0043] Embodiments of this disclosure generally relate to tailored in-ear audio devices, also referred to herein as in-ear audio devices, tailored headphones, or simply headphones. Embodiments of tailored headphones, including features that provide superior retention in a user's ear while maintaining desired comfort and sound quality, are disclosed below. Superior retention is generally provided by a curable filler material disposed within a sleeve, which deforms to conform to the shape of the user's ear when the curable filler material is cured. The level of comfort in the tailored headphones described herein is enhanced because at least a portion of the audio output element is movable independently or relative to the portion of the headphone containing the curable filler material, thereby allowing the audio output element to adapt to and comfortably fit within a given user's ear canal.

[0044] The following disclosures include improvements to the implementation of a custom in-ear audio device by reducing the size and / or construction of certain components in a portable in-ear audio device, and by improving the reliability of the process for forming the custom in-ear audio device. For example, disclosed improvements, such as reflective sound tubes and radiation sources (e.g., light-emitting diodes) included within the curable filler material, allow for the use of smaller radiation sources. These smaller radiation sources generate less heat than larger ones, which can be safer and more comfortable for the user during the curing process, and also allows for the use of smaller heat sinks. The reliability of a custom in-ear audio device can also be improved by reducing the variability in the curing rate of the curable filler material located at different locations within the custom in-ear audio device. Variations in the curing rate at different locations within the custom in-ear audio device can cause mechanical stresses that prevent the curable filler material from properly bonding to the surrounding sheath. Variations in the curing rate can be reduced by providing light more directly to the ear tip portion of the custom in-ear audio device (i.e., the portion of the device that extends into the user's ear canal). The following also discloses implementation methods that can improve the manufacturing process of forming custom-made headphones, such as manufacturing custom-made in-ear audio devices by using fewer manufacturing steps, making custom-made in-ear audio devices less expensive to manufacture.

[0045] Figure 1A This is a perspective view of an audio device customization system 50 according to one embodiment. The audio device customization system 50 includes an audio device 100 and external electronic devices 190. Although the audio device 100 is in Figure 1A While shown as a wireless earbud headphone, the audio device 100 described herein can include various types of in-ear audio devices for mono- or binaural use, such as wired or wireless in-ear monitors, wired or wireless earbuds, hearing aids, and any other wearable devices that can be used to provide, block, and / or otherwise control sound received by the user's ears. Furthermore, while external electronic devices 190 are... Figure 1A While shown as a mobile phone, external electronic device 190 can include any external electronic device that can include a user interface 191 (e.g., a touchscreen display) and communicate with audio device 100. Figure 1A In the audio device customization system 50 shown, an external electronic device 190 can be controlled by a user to control (e.g., activate) and monitor the customization process on the audio device 100 so that the in-ear headphones of the audio device 100 can be customized for an individual's ears. For example, the external electronic device 190 can be connected via a communication link 150 (e.g., a wireless communication link (e.g., a wireless communication link)). The link communicates with the audio device 100 to initiate a curing process on a curable filler material (e.g., a deformable photosensitive polymer) within the earbuds of the audio device 100. This communication can initiate the curing process by stimulating a radiation source (e.g., one or more light-emitting diodes (LEDs)) within the audio device 100. Alternatively, the curing process can be initiated when a user presses the earbuds of the audio device 100 firmly against their ear.

[0046] Audio device 100 includes two earbud-type headphone assemblies 101. Each earbud-type headphone assembly 101 includes a customizable earbud 102 and an audio component 111. The two earbud-type headphone assemblies 101 may be mirror images of each other, such that one earbud-type headphone assembly 101 is configured to be positioned in the user's left ear and the other earbud-type headphone assembly 101 is configured to be positioned in the user's right ear. As used herein, the term "mirror image" is intended to describe components that are substantially similar to each other in opposite orientations, and therefore the term "mirror image" is not intended to be interpreted narrowly as an exact inverted copy. Figure 1A One embodiment is provided in which the customizable earplugs 102 are substantially similar to each other in opposite orientations, as the ear tip portion 412 and the fin portion 419 are arranged oppositely, such that one earplug 102 can be inserted into the left ear and one earplug 102 can be inserted into the right ear. Generally, the two earbud-type headphone assemblies 101 are "mirror images" before each customizable earplug 102 is inserted into the user's ear and thus twisted to fit the user's ear and then fixed in place, as described below. Figure 8 As described in frames 2010-2016. Customizable earbuds 102 may be detachable from each corresponding audio component 111. Each customizable earbud 102 may contain a curable filler material disposed within a sleeve, which may at least partially deform during the curing process to conform to the shape of the user's ear. Each audio component 111 may include an audio driver (i.e., an audio speaker) and other components for delivering audio through the corresponding customizable earbud 102 to one of the user's ears.

[0047] The audio device 100 also includes a controller assembly 112 and a connector assembly 113. The controller assembly 112 and the connector assembly 113 are connected to each other and to the earphone assembly 101 by one or more cables 114. The cables 114 are generally flexible and configured to physically connect the controller assembly 112, the connector assembly 113, and the earphone assembly 101 together, and also allow electrical signals to pass through various links 231-233 formed between the controller assembly 112, the connector assembly 113, and the earphone assembly 101. Figure 2The controller assembly 112 can be used to control the operation of the audio device 100 during user use, such as by starting and stopping audio output and adjusting volume. However, in some embodiments, the controller assembly 112 can be used for other operations, such as initiating a curing process to conform the customizable earbud 102 to the shape of the user's ear, with or without the use of external electronics 190. The connection assembly 113 can be used to charge the power source of the audio device 100, such as one or more onboard batteries, and to provide power to a radiation source (e.g., a light-emitting diode) located within the customizable earbud 102 during the customization process. For example, the connection assembly 113 can be used to connect the audio device 100 to an external battery that is larger (e.g., has increased charging capacity, is heavier) than any power source included in the audio device 100. This external power source can provide energy for curing the curable filler material to conform the customizable earbud 102 to the unique shape of the user's ear.

[0048] Figure 1B This is an exemplary illustration of the human outer ear 20. A customizable earplug 102 is configured to conform to portions of the user's ear 20 for a snug and comfortable fit. The following is a description of these portions of the outer ear 20 and is helpful for understanding how the customizable earplug 102 conforms to the user's ear 20 in subsequent sections of this specification.

[0049] The outer ear 20 includes an ear canal 2 leading to the tympanic membrane (not shown). An earlobe 1 forms the lower portion of the outer ear 20, and a helix 6 extends from the earlobe 1 to the top portion of the outer ear 20. The ear canal 2 is surrounded by a concha 3, a crus of the helix 5, a tragus 10, and an antitragus 12. The concha 3 has a concave shape (e.g., a bowl shape) relative to the surrounding portion of the outer ear 20 other than the ear canal 2. A customizable earplug 102 can be placed within this concave shape of the concha 3, as described more fully below. The antitragus 12 is a projection extending from the earlobe 1 toward the ear canal 2. The tragus 10 is a projection extending from the face (not shown) toward and / or across the ear canal 2. The crus of the helix 5 is a spiky portion extending from above the tragus 10 into the concha 3. The antitragus 8 is disposed between the helix 6 and the crus of the helix 5. The antihelix 8 is separated from the helix foot 5 by the concha 4, and the concha 4 is recessed relative to the helix foot 5 and the antihelix 8. The portion of the antihelix 8 that connects to the concha 4 is the lower helix foot 14. The portion of the antihelix 8 that extends to the helix 6 is the upper helix foot 16.

[0050] Figure 1CThis is a perspective view of an earbud-type headphone assembly 101 according to one embodiment, including a customizable earbud 102 disposed within a portion of the outer ear 20 after the user customizes the customizable earbud 102 to conform to the shape of the user's ear 20. The customizable earbud 102 includes an ear tip portion 412, which has been positioned within the user's ear canal 2 and concha 3 and conforms to the shape of the user's ear canal 2 and concha 3. The customizable earbud 102 may also include a body portion 415. Figure 4 The main body portion 415 is adapted to conform to the shape of at least a portion of the user's concha 3, helix 5, and / or cymba concha 4. The main body portion 415 may also include a fin portion 419, opposite to the ear tip portion 412, and adapted to fit snugly against the cymba concha 4 and rest beneath the antihelix 8 and / or the lower antihelix 14 when the customizable earplug 102 is disposed within a portion of the outer ear 20. When the user presses the earbud assembly 101 toward the user's ear, the ear tip portion 412 and the main body portion 415 can conform to the shapes of different portions of the user's ear as described above, and the curable filler material within the customizable earplug is cured, allowing the customizable earplug to maintain a unique fit to the shape of the user's ear.

[0051] Figure 2 This is a schematic diagram of an audio device customization system 50 according to one embodiment, including... Figure 1A The diagram shows a block diagram of an audio device customization system 50. Figure 2 Also includes the audio equipment customization system 50 Figure 1A Other components not shown.

[0052] Each audio component 111 may include an earphone electronics component 210, which includes components for assisting in delivering audio to a user via a correspondingly attached, customizable earpiece 102. For example, each earphone electronics component 210 may include a memory 212, a processor 211 coupled to the memory 212, and a portable power supply 216 (e.g., a battery) for powering the components in the earphone electronics component 210. The memory 212 may 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, for example, audio data). For example, the processor 211 may be a central processing unit (CPU), a digital signal processor (DSP), an application-specific integrated circuit (ASIC), or a combination of such units. The processor 211 is configured to execute software applications, process audio data, communicate with I / O devices, and perform other operations.

[0053] Memory 212 can be any technically feasible type of hardware unit configured to store data. For example, memory 212 can 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 applications within memory 212 can include program code (e.g., instructions) that can be executed by processor 211 to perform various functions associated with the audio device, such as playing or adjusting audio output and / or activating a radiation source to cure the filling in the customizable earbud 102 for a desired period of time.

[0054] The earphone electronics 210 may also include I / O devices 213, such as a microphone assembly or sensors (e.g., pressure sensors), 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, for example, reducing the volume provided to the user when the user is speaking. For example, in one embodiment, the microphone assembly may include multiple microphones, such as a first microphone configured to receive a first audible signal from an external source (i.e., outside the audio device 100) and a second microphone configured to receive a second audible signal being provided to the user through a sound tube, thereby enabling the audio device 100 to determine the relative difference between the two audible signals and then allowing the audio device 100 to adjust the sound level of the second audible signal and / or improve the level of sound insulation experienced by the user. In one embodiment, the earphone electronics 210 may include multiple pressure sensors at different locations within the earphone electronics 210. These multiple pressure sensors can be used to provide feedback to the user during the customization process to assist the user in applying different or more uniform pressure at different parts of the earphone electronics 210. Applying more uniform pressure at different locations on the earbud electronics 210 can help the user achieve better results with the earbuds 102 customized for the user's ears. In some embodiments, one or more pressure sensors may be alternatively located within one of the earbuds 102, for example, in a curable filler material disposed within the earbud 102. Audio drivers 214 are used to generate an audible output (e.g., one or more audio signals with a frequency >200 Hz) provided to the user of the audio device 100. While only one audio driver 214 is shown, in some embodiments, each earbud electronics 210 may include two or more audio drivers that can be used to generate a high-quality audio output commonly associated with certain types of audio devices, such as in-ear monitors. In some embodiments, the audio driver 214 may be a balanced armature driver, such that current flows through a coil wound around an armature. In other embodiments, the audio driver 214 may be a dynamic driver, such that a diaphragm is directly attached to a voice coil that moves between one or more magnets.

[0055] I / O device 213 and audio driver 214 may also be coupled to processor 211 and memory 212. In some embodiments, each earphone electronics 210 may include additional I / O devices (not shown) capable of receiving various inputs and / or providing various desired outputs. These additional I / O devices may include one or more outputs (e.g., control relays) for controlling other outputs of earphone assembly 101 (e.g., radiation source 215 described below). These I / O devices may also include one or more signal processing support components, signal filtering components (e.g., low-pass and / or high-pass filters), and components (e.g., signal amplifiers) for enabling audible outputs from audio driver 214 to be transmitted.

[0056] Each audio component 111 is attached to a corresponding customizable earbud 102. In one embodiment, each customizable earbud 102 includes a plurality of radiation sources 215. In some embodiments, the plurality of radiation sources may be embedded in a curable filler material disposed within the customizable earbud 102. In other embodiments, one or more radiation sources 215 are disposed within the housing of the audio component 111 and adjacent to the surface of the customizable earbud 102, as referenced below. Figures 15A-15B Further discussion follows. In some embodiments, each radiation source 215 may be an electromagnetic radiation source, such as a light source emitting wavelengths in the visible wavelength range and / or ultraviolet (UV) wavelengths. In some embodiments, each radiation source 215 is configured to emit light at one or more wavelengths below the infrared range (e.g., <750 nm). For example, in one embodiment, radiation source 215 includes a light-emitting diode (LED) emitting radiation at wavelengths from about 345 nm to about 420 nm, such as about 405 nm, which may be used to cure filler disposed in customizable earplug 102. Although the embodiments described in this disclosure are described as including multiple radiation sources 215, in some embodiments, a single radiation source (e.g., a single LED) may also be used. Furthermore, in some embodiments, radiation sources disposed outside the audio device 100 may additionally or alternatively be used to supply energy into the customizable earplug 102, for example, LEDs capable of emitting energy through a permeable portion of the exterior of the customizable earplug 102 into the customizable earplug 102.

[0057] Each customizable earbud 102 may also include a flexible printed circuit board (PCB) 217 ​​and one or more support elements (see...). Figure 4(Support spacer 402 in the middle). The plurality of radiation sources 215 can be placed on the flexible PCB 217. In some embodiments, the flexible PCB 217 and the radiation sources 215 can be arranged in a curable filler material of the customizable earplug 102 such that at least one surface of the flexible PCB contacts the curable filler material. The one or more support elements can be used for purposes such as supporting the flexible PCB 217 in a suitable position within the customizable earplug 102 so that the energy from the radiation sources 215 can efficiently and effectively cure the curable filler material arranged in the customizable earplug 102. It is generally believed that positioning the radiation sources 215 within the curable filler material will improve the ability of the radiation sources 215 to efficiently and effectively cure the curable filler material arranged in the customizable earplug 102 because, if an air gap exists between the housing of the radiation source 215 and the curable filler material, then a reduced amount of reflection will be produced due to the change in refractive index found at the air gap / radiation source housing interface and the air gap / curable filler material interface.

[0058] The audio device 100 also includes a controller assembly 112, which is coupled to each earbud assembly 101 via one or more cables 114 (see...). Figure 1A The controller assembly 112 may include a memory 202, a processor 205 coupled to the memory 202, one or more I / O buttons (e.g., volume buttons, command buttons, power buttons) for receiving user input, and a portable power supply 206 (e.g., a battery) for powering components in the controller assembly 112. The memory 202 may include data (e.g., audio data) and one or more applications stored therein. The processor 205 may be any hardware unit or combination of hardware units capable of executing software applications and processing data (including, for example, audio data). For example, the processor 205 may be a central processing unit (CPU), a digital signal processor (DSP), an application-specific integrated circuit (ASIC), or a combination of such units. The processor 205 is configured to execute software applications, process audio data, communicate with I / O devices, communicate with earphone electronics 210 in the respective earphone assemblies 101, and perform other operations. For example, the processor 205 of the controller assembly 112 may be configured to communicate with the processor 211 in each of the respective earphone electronics 210 via a data link 231 (e.g., a wired communication link). Data link 231 can be used to control the operation of audio device 100, including, in some embodiments, controlling the curing process for customizable ear tips 102.

[0059] The memory 202 can be any technically feasible type of hardware unit configured to store data. For example, the memory 202 can 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 applications within the memory 202 can include program code that can be executed by the processor 205 to perform various functions associated with the audio device 100, such as playing or adjusting audio output, activating the radiation source 215 for curing the curable filler material disposed in the customizable earpiece 102, and interacting with external devices, such as… Figure 1A The external electronic device 190 shown communicates.

[0060] To avoid redundancy, in some embodiments of the audio device 100, the memory 202 and processor 205 may be the only processing units within the audio device 100, and therefore multiple discrete processors and memories will not be found within the audio device 100. In one configuration, any activities or processing that would normally be performed by the processor 211 and memory 212, if present in the audio component 111, are performed using the memory 202 and processor 205 of the controller component 112.

[0061] The controller assembly 112 may also include a transceiver 203 and an I / O device 204. In some embodiments, the transceiver 203 may be a wireless transceiver. The transceiver 203 may be configured to establish one or more different types of wireless communication links with other transceivers residing in other electronic devices, such as external electronic device 190. For example, the transceiver 203 may establish a Wi-Fi communication link with other electronic devices, such as external electronic device 190. Communication links or near-field communication (NFC) links, and other types of communication links. I / O device 204 may include input sections (e.g., a 3.5mm audio input jack) for receiving audio input from an external wired audio source (not shown). I / O device 204 may also include output sections and other input sections, such as one or more status indicators (e.g., LEDs) and buttons or switches for controlling and / or monitoring the operation of audio device 100, including starting and stopping audio playback and assisting in controlling and / or monitoring the curing process of a curable filler material disposed in customizable earbuds 102.

[0062] The controller assembly 112 may also include a power controller 220. The power controller 220 may be used to control the supply of power from an external power source to the radiation source 215 of the customizable earbud 102 during the curing process. For example, the power controller 220 may be electrically coupled to an external power source 301 via a connection assembly 113. The power controller 220 may be coupled to the radiation source 215 via a power link 233 (e.g., a wired connection). The power controller 220 may be used to control the voltage and / or amperes supplied to the radiation source 215 via the power link 233 during the curing process. In some embodiments, the power controller 220 may also be used to recharge the portable power source 216 in each of the respective earbud assembly 101 using a source power link 232. Furthermore, in some embodiments, the power controller may be located in each earbud assembly 101, rather than in the controller assembly 112.

[0063] The external power supply 301 described above can be connected to the audio device 100. The external power supply 301 may include a portable power source 304 (e.g., a battery) and a power connector 302. The portable power source 304 can supply substantially more power (e.g., ampere-hours) than the power source within the audio device 100, such as other portable power sources 206, 216 described above. As used herein, the term "portable power source" generally describes a power source that is easily movable when not connected to a fixed power source such as a wall outlet or plug and is capable of supplying power to the electronic components in the audio device. The portable power source 304 can be used to supply power to the radiation source 215 during the curing process. The power connector 302 can electrically couple the external power supply 301 to the connection assembly 113 of the audio device 100 (see also...). Figure 1A The external power supply 301 may also include other connectors (not shown) for supplying external power to the portable power supply 304, such as a USB connector for charging the portable power supply 304 via an electronic device or wall-mounted power supply that accepts a USB connector. In some embodiments, the external power supply 301 may include a wired power supply instead of the portable power supply 304 described above.

[0064] Audio device 100 can communicate with external electronic device 190 while the audio device 100 is in use by a user. For example, external electronic device 190 can be controlled by the user to control (e.g., activate) and monitor a customization process on audio device 100 so that earphones on audio device 100 can be customized for the user's ears. External electronic device 190 can also be used to stream audio content to audio device 100 for listening by the user. External electronic device 190 can communicate with audio device 100 via communication link 150, which can be a wireless communication link.

[0065] External electronic device 190 may include memory 196, processor 195 coupled to memory 196, and power supply 198 (e.g., battery) for powering components in external electronic device 190. Memory 196 may include data (e.g., audio data) and one or more applications stored therein. Memory 196 may be any technically feasible type of hardware unit configured to store data. For example, memory 196 may be a hard disk, random access memory (RAM) module, flash memory unit, or a combination of different hardware units configured to store data. Software applications within memory 196 may include program code that can be executed by processor 195 to perform various functions associated with external electronic device 190, such as streaming audio content to audio device 100 and providing a customized user interface for user control of earpiece 102.

[0066] Processor 195 can be any hardware unit or combination of hardware units capable of executing software applications and processing data (including, for example, audio data). For example, processor 195 can be a central processing unit (CPU), a digital signal processor (DSP), an application-specific integrated circuit (ASIC), or a combination thereof. Processor 195 is configured to execute software applications, process audio data, communicate with I / O devices, communicate with the controller component 112 of audio device 100, and perform other operations.

[0067] External electronic device 190 may also include a transceiver 193 for communicating with controller component 112 of audio device 100 via communication link 150. Communication link 150 may also be used for streaming audio content from external electronic device 190 to audio device 100 and for communication to audio device 100 during use with custom earplugs 102 on a user's ear. In some embodiments, transceiver 193 may be a wireless transceiver. Transceiver 193 may be configured to establish one or more different types of wireless communication links with other transceivers residing in other electronic devices, such as audio device 100. For example, transceiver 193 may establish a Wi-Fi communication link with other electronic devices, such as audio device 100. Communication links or near field communication (NFC) links, as well as other types of communication links.

[0068] External electronic device 190 may also include speaker 197. Speaker 197 can be used for various operations, including providing audio instructions and feedback to the user before, during, and after the process of customizing the earplugs 102 for the user's ears. External electronic device 190 also includes the features described above. Figure 1AThe user interface 191 described herein can also be used to assist the user during the customization process and to assist in streaming audio content from external electronic device 190 to audio device 100.

[0069] Figure 3 This is a perspective view of an audio device 100 and an external power supply 301 according to one embodiment. Customizable earbuds 102 are shown as being mounted from... Figure 3 The audio component 111 of the left earbud-type headphone assembly 101 is disconnected. In some embodiments, the user can selectively choose different customizable ear tips 102. For example, different customizable ear tips 102 may have different sizes and / or shapes, each better suited to match users with different ear anatomy. Furthermore, the user can selectively choose customizable ear tips 102 based on style preferences (e.g., color) or comfort preferences (e.g., texture and hardness). Making the customizable ear tips 102 detachable from the audio component 111 also allows the user to easily replace the customizable ear tips 102 for any reason without incurring significant costs, as the customizable ear tips 102 are typically substantially less expensive than the audio component 111. For example, users can switch between different styles and sizes of the customizable earbuds 102, easily replace malfunctioning or damaged customizable earbuds 102, and also allow other users to use the audio device 100 for different users by simply attaching the customizable earbuds 102.

[0070] External power supply 301 is shown disconnected from audio device 100 to illustrate different features of external power supply 301 and connection assembly 113 of audio device 100. External power supply 301 may include a first cable 305 for connecting portable power supply 304 to power connector 302. External power supply 301 may also include a second cable 306 (e.g., USB cable) for connecting portable power supply 304 to an external power source for charging portable power supply 304.

[0071] The connector assembly 113 may include a plurality of connector terminals 113A for connection to corresponding terminals (not shown) of the power connector 302. The power connector 302 may include a channel 309 for receiving the connector assembly 113. In some embodiments, one or more of the power connector 302 and the connector assembly 113 may include a magnetic material configured to be attracted to a magnetizable material in another connector to facilitate the creation and maintenance of an electrical connection between the power connector 302 and the connector assembly 113.

[0072] Figure 4This is an exploded view of one of the earphone assemblies 101 of an audio device 100 according to one embodiment. Figure 5 This is a plan view of a customizable earplug 102 according to one embodiment. Figure 4 In the diagram, audio component 111 is shown with the output of audio driver 214 facing customizable earbud 102. In one embodiment, customizable earbud 102 includes connector 405. Connector 405 can be used to detachably couple and electrically connect electrical components disposed within customizable earbud 102 to audio component 111. Male connector 405 can be inserted into... Figure 4 The female connection point 405A is shown in the diagram. For example, connector 405 can be used to provide an electrical connection to a radiation source 215 for curing a curable filler material disposed in a customizable earpiece 102. Connector 405 allows the customizable earpiece 102 to be easily and detachably attached and removed from the audio assembly 111. However, in some embodiments, as referenced below... Figure 15A -15C Further discussion suggests that the customizable earbuds 102 may optionally include connector 405. As in Figure 3 and 4 As shown, audio component 111 may include protrusion 111A ( Figure 4 The protrusion 111A is configured to be inserted into the mating recess 102A. Figure 3 This allows the customizable earbud 102 and audio component 111 to be detachably coupled or detachably attached to each other, and thus can be attached, detached, and reattached multiple times without significantly damaging or degrading the mating surfaces, interface materials, or interface structural elements. In one embodiment, the outer diameter of the protrusion 111A can be controlled to be slightly larger than the size of the recess 102A to provide a slight interference fit between these features and thus allow the components to be detachably coupled and also provide a seal between the audio component and the input end of the sound tube 422 to prevent unwanted sound leakage at the interface between the customizable earbud 102 and audio component 111. The protrusion 111A and the mating recess 102A, serving as detachable coupling portions when desired by the user, can be particularly useful in configurations where the connector 405 and the female connection point 405A are not, respectively, part of the customizable earbud 102 and the audio component 111. In some embodiments, the structure of the joint formed between components forming a separably coupled coupling does not require any additional tools or materials (e.g., adhesives) for the formation of the joint and the non-formation of the joint (i.e., parts to be attached or detached).

[0073] The customizable earbud 102 also includes a sleeve assembly 401. The sleeve assembly 401 forms an enclosure to house components within the customizable earbud 102, such as a curable filler material, a flexible PCB 217, and a radiation source 215. The sleeve assembly 401 may contain a flexible and deformable material capable of conforming to the shape of the user's ear during the curing process. The sleeve assembly 401 includes a collar 411 of a sleeve 600. Figure 4 ( ) part. The collar 411 can be used to retain the component within the sleeve assembly 401, as described below. Figure 6 As shown in the diagram, the earpiece assembly 401 also includes an ear tip 412 for providing audio to the user during use of the earbud assembly 101. The ear tip 412 can be placed in the user's ear canal during use of the audio device 100.

[0074] The sleeve component 401 may include a sleeve 600 that contacts the user's ear (see [link to sleeve 600]). Figure 6 The sleeve 600 may optionally include an inner cover 601, as discussed further below. The sleeve 600 may be formed of a biocompatible material that conforms to the individual shape of the user's ear while maintaining sufficient tear and puncture resistance and acting as a barrier layer to prevent the curable filler material from contacting the user. Sufficient bonding between the inner surface of the sleeve body (i.e., the inner surface of the sleeve 600 or the inner cover 601) and the curable filler material also helps prevent tearing of the sleeve 600 when force is applied to the sleeve assembly 401 by the user. The sleeve 600 may be formed of a flexible material, such as an elastic material that tends to return to its original shape after force has been applied and removed from the elastic material. Suitable materials for forming the sleeve 600 include siloxanes, fluorosiloxanes, nitrile materials, acrylates, high-consistency rubbers (HCRs), and thermoplastic elastomers (e.g., thermoplastic polyurethanes (TPUs), such as aliphatic TPUs).

[0075] Set 600 (see) Figure 6 The sleeve assembly 401 can be formed using various molding processes, such as compression molding, injection molding, and dip molding. The sleeve assembly 401 can have a thickness from about 0.5 mm to about 1.2 mm, for example from about 0.7 mm to about 1.0 mm, such as about 0.75 mm. The sleeve assembly 401 can have a hardness from about 25 Shore A to about 45 Shore A, for example from about 30 Shore A to about 40 Shore A. In some embodiments, as further discussed below, the sleeve 600 is formed such that it includes different thicknesses in different regions of the sleeve 600.

[0076] The customizable earbud 102 also includes a sound tube assembly 403. The sound tube assembly 403 includes a sound tube 422. The sound tube 422 includes an input section 425 and an output section 426. The input section 425 is disposed at the input end of the sound tube 422 and adjacent to an opening formed in the protrusion 111A. The sound tube 422 is used to transmit 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 section 425 of the sound tube 422 and then transmitted through the sound tube to the output section 426 of the sound tube 422 and then through the ear tip 412 of the earpiece assembly 401 to the user.

[0077] The sound tube assembly 403 also 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 internally supported by the collar 411 of the sleeve assembly 401, as described below. Figure 6 As shown in the diagram. The sound tube assembly 403 also includes a plurality of tubes 423. In some embodiments, the plurality of tubes 423 may be used to add a curable filler material to the interior of the sleeve assembly 401 after the sound tube assembly 403 has been positioned in the sleeve assembly 401. Other portions of the sound tube 422 and the sound tube assembly 403, such as the base 421 and the tubes 423, may be formed of a thermoplastic elastomer (e.g., thermoplastic polyurethane (TPU), siloxane, polycarbonate, acrylonitrile butadiene styrene, or polypropylene). In one embodiment, the sound tube 422 and other portions of the sound tube assembly 403 are formed of an opaque white TPU material capable of providing diffuse reflection of light from the radiation source 215, which facilitates complete curing of the curable filler material. In some embodiments, the sound tube assembly 403 may also include fasteners for connecting other components to the sound tube assembly 403, such as the flexible PCB 217 and the support portion 404 described below. The sound tube 422 and other parts of the sound tube assembly 403 may have a hardness from about 60 Shore A to about 120 Shore A, for example about 90 Shore A.

[0078] The customizable earbud 102 also includes a support 404 disposed between the collar 411 of the sleeve assembly 401 and the audio assembly 111. The support 404 may be formed of a more rigid material than the sleeve assembly 401 to provide structural support for the customizable earbud 102. The base 421 of the sound tube assembly 403 may also be connected to the support 404. For example, in one embodiment, the support 404 is connected to the base 421 of the sound tube assembly 403 using fasteners. Figure 4 ).

[0079] A flexible PCB 217 may be positioned between the base 421 of the sound tube assembly 403 and the output area 426 of the sound tube assembly 403. In some embodiments, the flexible PCB 217 may have a ring or partially ring shape, such that the flexible PCB 217 at least partially surrounds the sound tube 422. Multiple radiation sources 215, such as LEDs, may be arranged on the flexible PCB 217. Arranging multiple radiation sources 215 on the flexible PCB 217 surrounding the sound tube 422 (i.e., as opposed to a non-flexible PCB) helps prevent the user from feeling the presence of the PCB during use of the audio device 100, while also reducing the possibility that a rigid portion of a non-flexible PCB might puncture the housing assembly 401. The flexible PCB 217 may also include a heat conduction component larger than a normal copper ground plane to act as a heat sink, removing heat generated by the radiation sources 215 during the customization process and transferring it to the audio assembly. In some embodiments, a current from about 50mA to about 150mA, for example about 100mA, can be supplied to the radiation source 215 during the customization process. In some embodiments, the flexible PCB 217 or the power controller 220 (see...) Figure 2 The voltage supplied from external power source 301 can be increased to reduce the amperage and decrease the heat generated by radiation source 215 during the curing process. For example, in one embodiment, power from external power source 301 at a voltage of approximately 3V can be increased to a level of approximately 15V, which is supplied to radiation source 215. In one embodiment, power controller 220 is configured to supply a fixed maximum current to radiation source 215 during the curing process to prevent the curable filler material from reaching temperatures that are uncomfortable for the user.

[0080] The plurality of radiation sources 215 may be spaced apart from each other around the flexible PCB 217 to reduce the maximum distance between the radiation sources 215 and the portions of the curable filler material disposed within the sleeve assembly 401, such as the portion of the curable filler material disposed within the ear tip 412 of the sleeve assembly 401. In one embodiment, each radiation source 215 may have a particularly small occupying area within the sleeve assembly 401, for example, about 1.6 mm by about 1.6 mm. In some embodiments, a support spacer 402 may be positioned between the base 421 of the sound tube assembly 403 and the flexible PCB 217 to allow for further precise positioning of the radiation sources 215 within the sleeve assembly 401. In some embodiments, the flexible PCB 217 may be connected to the sound tube assembly 403, for example, by using fasteners connected to the base 421 of the sound tube assembly 403.

[0081] Figure 5 This is a perspective view of an earbud-type headphone assembly 101 according to one embodiment. Figure 5In the middle, section line 6-6 extends from the ear tip 412 of the sleeve assembly 401 and passes through the customizable ear tip 102 and the audio assembly 111.

[0082] Figure 6 It is according to one implementation method along Figure 5 The cross-sectional view of the earphone assembly 101 taken by section line 6-6. Figure 6 An embodiment is illustrated, showing how different components in the customizable earbud 102 and audio assembly 111 are matched together within the earbud headphone assembly 101.

[0083] In some embodiments, the sleeve body of sleeve assembly 401 includes sleeve 600 and inner cladding 601. In one configuration, sleeve 600 may be formed of a material such as siloxane, fluorosiloxane, nitrile, acrylate, high-consistency rubber (HCR), and thermoplastic elastomer (e.g., thermoplastic polyurethane (TPU), such as aliphatic TPU). Inner cladding 601 may have a thickness from about 50 μm to about 200 μm, for example, about 100 μm. In one embodiment, inner cladding 601 may be formed of a siloxane material comprising a reflective material such as titanium dioxide, silver, or aluminum oxide. In one embodiment, inner cladding 601 comprises titanium dioxide having a particle size from about 100 nm to about 200 nm, for example, about 150 nm. In some embodiments, inner cladding 601 may be evaporated onto sleeve 600, coated onto sleeve 600, sputtered onto sleeve 600, printed onto sleeve 600, or sprayed onto sleeve 600. The inner cladding 601 can be used to form a barrier layer and / or a reflective surface that reflects energy emitted from the radiation source 215. For example, in one embodiment, the radiation source 215 emits radiation at a wavelength of about 405 nm, and the inner cladding 601 is configured to reflect substantially all radiation having a wavelength of 405 nm, for example, a material having a reflectivity greater than 95% for radiation having a wavelength of 405 nm, or a material having a reflectivity greater than 99% for radiation having a wavelength of 405 nm.

[0084] While the sleeve body of sleeve assembly 401 is generally described herein as including a reflective inner cladding, in some embodiments, the material used to form sleeve 600 may be reflective, such as a polymer embedded with a reflective material, for example, a siloxane sleeve having titanium dioxide embedded in a siloxane. In some embodiments, the sleeve body includes sleeve 600 containing reflective material therein, and does not include the inner cladding 601. However, in embodiments where the material used to form sleeve 600 is reflective of radiation from radiation source 215, the inner cladding 601 may still be included within the sleeve body. In such embodiments, the inner cladding can function as a barrier layer to prevent the migration of curable filler material into or through sleeve 600, while also being permeable to radiation from radiation source 215, allowing the radiation to be reflected by the material found within sleeve 600.

[0085] A sound tube assembly 403 is disposed within a sleeve assembly 401 and includes a sound tube 422. The sound tube 422 extends from an input region 425 to an output region 426 to transmit sound received from the audio driver 214 at the input region 425 to the user via the output region 426. An internal volume 610 is located in the empty space between the sleeve assembly 401 and components within the sleeve assembly 401, such as the sound tube assembly 403. A curable filler material for customizing the earplug 102 for the user's ear can be added to the internal volume 610 during the manufacturing process.

[0086] The sleeve assembly 401 may also include an inwardly projecting portion 622 formed on the sound tube 422 at the output area 426 of the sound tube 422. The inwardly projecting portion 622 may surround a portion of the length of the sound tube 422 without obstructing the output area 426 of the sound tube 422. The customizable earplug 102 may also include a retaining ring 615 to assist in retaining the inwardly projecting portion 622 to the sound tube 422. The inwardly projecting portion 622 may include a notch 623 for receiving the retaining ring 615. The notch 623 helps prevent the retaining ring 615 from moving after the inwardly projecting portion 622 has been secured to the sound tube 422. In one embodiment, the retaining ring 615 may be a resilient ring. In other embodiments, the retaining ring 615 may be omitted, and the sound tube 422 at the output area 426 may be secured to a portion of the sleeve assembly 401 (i.e., the same or similar portion as the inwardly projecting portion 622) by welding or other methods.

[0087] The sound tube assembly 403 may also include an outer cladding 602. The outer cladding 602 may form a reflective surface that reflects energy emitted from the radiation source 215. In one embodiment, the outer cladding 602 of the sound tube assembly 403 may be formed of the same material as the inner cladding 601 of the sleeve assembly 401, such as a siloxane having a reflective material (e.g., titanium dioxide) embedded in it. Furthermore, in some embodiments, all surfaces within the sleeve assembly 401 that may be exposed to radiation from the radiation source 215 may be configured to be covered with a reflective material that reflects energy emitted from the radiation source 215, such as the same material used for the inner cladding 601 of the sleeve assembly 401. In other embodiments, the sound tube 422 and other components within the sleeve assembly 401 may be formed of a reflective material, such as a polymer loaded with a certain amount of reflective material, such as a siloxane material having titanium dioxide embedded in it.

[0088] A support spacer 402 is disposed on the base 421 of the sound tube assembly 403. A flexible PCB 217 is disposed on the support spacer 402. The plurality of radiation sources 215 are disposed on the flexible PCB 217. As mentioned above, in some embodiments, a connector 405 is used to attach a customizable earbud 102 to the audio assembly 111. The connector 405 may be attached to a component of the customizable earbud 102 during manufacturing, for example, by fastening it to a support 404. A portion of each connector 405 may extend into or completely through the support 404 as part of providing an electrical connection to the radiation source 215. The connector 405 may receive power from a power link 233 when the customizable earbud 102 is connected to the audio assembly 111. The power link 233 may receive power from an external power source 301, such as in Figure 2 As shown, this allows the audio device 100 to remain lightweight and portable because the power source used to excite the radiation source 215 comes from an external source that is not part of the audio device 100.

[0089] The audio assembly 111 also includes a housing comprising an outer shell 111B and a cover 111C. In some embodiments of the housing, the cover 111C includes a protrusion 111A having an opening that allows sound from the one or more audio drivers 214 to be injected into the input area 425 of the sound tube 422. The outer shell 111B and the cover 111C are configured to support and enclose the components found within the earbud-type headphone electronics 210 discussed above, which will include at least components that assist in delivering audio to the user via corresponding attached customizable earbuds 102 (e.g., audio drivers 214).

[0090] Figure 7This is a cross-sectional view of the customizable earbud 102 after the curable filler material 801 has been added to the customizable earbud 102 according to one embodiment. In some embodiments, the curable filler material 801 is a curable photosensitive polymer (e.g., polyurethane acrylate, siloxane, or fluorosiloxane) capable of retaining a desired fixed shape after a curing process while still maintaining an appropriate amount of flexibility after the curing process to accommodate movement in the ear canal and stress placed on the curable filler material 801 during use of the audio device 100. For example, the curable filler material 801 can be cured by exposing it to electromagnetic radiation (e.g., visible or ultraviolet light) provided from a radiation source 215. In other embodiments, the curable filler material 801 can be another type of curable filler material, such as a chemically curable filler material (e.g., reactive epoxy resin, polyurethane acrylate, or siloxane).

[0091] The curable filler material 801 can be formed from a material that is biocompatible in both its uncured and cured states, ensuring that potential contact with the user's skin does not irritate or harm the user. In embodiments where the curable filler material 801 is a photosensitive polymer, the curable filler material 801 may contain a concentration of photoinitiator to allow the curable filler material 801 to cure within about 30 seconds to about 120 seconds, for example, within about 60 seconds. In some embodiments, the curable filler material 801 comprises a polymeric material, such as a siloxane material. In some embodiments, the curable filler material 801 comprises a fluoropolymer material, such as a fluorinated siloxane material. In one embodiment, the curable filler material 801 comprises fumed silica to enhance the mechanical properties of the curable filler material 801. The curable filler material 801 may have a viscosity from about 15,000 cP to about 1,000,000 cP before curing, for example from about 50,000 cP to about 120,000 cP, such as about 80,000 cP. In some embodiments, the curable filler material 801 may have a hardness from about 20 Shore A to about 50 Shore A after curing, for example about 30 Shore A after the curing process has been carried out. In some embodiments, the curable filler material 801 may cure in about 30 seconds to about 120 seconds, for example in about 60 seconds. Furthermore, both the curable filler material 801 and the sleeve assembly 401 may 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 headphones are rigid and inflexible after customization, which can pose many problems for the user. For example, as a user ages, gains or loses weight, the contour of their ear can change slightly but still significantly. These small changes in the user's ear can cause the experience of a user of typically rigid and non-flexible custom-fit headphones to deteriorate over time in terms of fit, comfort, and performance. On the other hand, in this disclosure, by maintaining the flexibility of the curable filler material 801 and the sleeve assembly 401, the user can enjoy consistent fit, comfort, and performance during use of flexible custom-fit ear tips 102 that can adjust to the contour of the user's ear and undergo small changes over time. Furthermore, maintaining the flexibility of the custom-fit ear tips 102 after curing also prevents the ear tips 102 from rubbing or otherwise damaging or irritating the user when inserting and removing them from the user's ear.

[0092] In some embodiments, the curable filler material 801 is selected such that it is bonded to the material used to form the inner cladding 601 and / or the material used to form the sleeve 600 to prevent relative movement between the sleeve assembly 401 and the cured curable filler material 801 during normal use by the user. Relative movement between the sleeve assembly 401 and the cured curable filler material 801 can cause the material in the sleeve assembly 401 to “clump together” in certain areas of the customizable earplug 102, which can make the customizable earplug 102 uncomfortable for the user to wear when loads are applied to the customizable earplug 102 during insertion into the user's ear or other normal use. The bonding formed between the curable filler material 801 and the inner coating 601 and / or the material used to form the sleeve 600 body can be desiccated by selecting compatible materials that allow for molecular-scale mixing, chain entanglement, and / or chemical bonding at the interface between the cured curable filler material 801 and the inner coating 601 and / or the material used to form the sleeve 600. In one embodiment, each of the curable filler material 801 and the inner coating 601 and / or the material used to form the sleeve 600 comprises a siloxane material. Another consideration when selecting the curable filler material 801 and the material used for the sleeve assembly 401 is to prevent the migration of the curable filler material 801 through the sleeve body of the sleeve assembly 401 in its uncured state. It has been found that selecting a material that is compatible with the sleeve assembly 401 and the curable filler material 801, yet still flexible, is important for preventing the migration of the uncured or cured filler material 801 into or through the sleeve assembly 401. The materials used 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 earplug 102 can be vacuum-sealed for packaging, placed in an opaque package, and / or maintained in a controlled environment before customer use to enhance the shelf life of the customizable earplug 102. In some embodiments, fluorosiloxanes contained in the sleeve assembly 401, such as part of the sleeve 600 or inner cladding 601, can prevent migration of the curable filler material 801 described above.

[0093] Figure 8 This is a process flow diagram of a method 2000 for customizing an audio device 100 for a user's ear according to one embodiment. Although the method steps are described with reference to the systems and components shown in Figures 1-7, those skilled in the art will understand that any system configured to perform the method steps in any order is within the scope of this disclosure provided herein.

[0094] Referring to Figures 1-7, method 2000 is described. In box 2002, a portable power supply 304 (see Figure 1-7) is provided to an external power supply 301. Figure 3Charging allows sufficient power to be supplied to the radiation source 215 in the customizable earbud 102 during the curing process (see...). Figure 6 ).

[0095] In box 2004, audio device 100 can be paired with external electronic device 190 (e.g., (Pairing process) (see) Figure 1A This allows users to control and monitor the curing process from external electronic devices.

[0096] In frame 2006, an external power supply 301 can be attached to the connection assembly 113 of the audio device 100 (see...). Figure 3 For example, the connection assembly 113 can be placed within the channel 309 of the power connector 302.

[0097] In frame 2008, the user can select and attach customizable earbuds 102 to the corresponding audio component 111 (see [link]). Figure 3 Users can choose customizable ear tips 102 based on size, comfort, and style preferences. Users can attach customizable ear tips 102 to corresponding audio components 111 using connectors 405 on the customizable ear tips 102.

[0098] In box 2010, the user can insert the customizable earpiece 102 of the audio device 100 into the user's ear. For example, the user can insert the ear tip 412 of the customizable earpiece 102 (see [link to audio device 100]). Figure 4 The customizable earplugs 102 are inserted into the user's respective ear canals. In box 2010, the user should not apply any significant pressure when the customizable earplugs 102 are inserted into the user's ears. In box 2012, a sound check is performed to ensure that the external electronic device 190 communicates properly with the audio device 100.

[0099] In box 2014, the user can press the start button in a software application running on external electronic device 190 to initiate a customization process to cure the curable filler material 801 arranged in the sleeve assembly 401 of the customizable earbud 102 (see [link]). Figure 7 External electronic device 190 or audio device 100 may delay the actual start of the curing process, for example, by ten seconds, to allow the user time to reposition their hand to the audio device 100.

[0100] In frame 2016, the user can press firmly against the audio component 111, pushing the customizable earbud 102 toward the user's ear, allowing the curable filler material 801 and the sleeve component 401 to deform and conform to the shape of the user's ear. Furthermore, in frame 2016, the actual curing process occurs when power is supplied from an external power source 301 via a portable power supply 304 (see...). Figure 3Radiation source 215 supplied to customizable earbud 102 (see) Figure 6 The power supply can continue to the radiation source 215 for a specified period of time, such as approximately 60 seconds, to allow the curable filler material 801 (see...) to cure. Figure 7 It can be cured more completely.

[0101] During the process in frame 2016, the temperature of the curable filler material 801 can be monitored using a temperature sensing device (not shown) found in the I / O device 213 located within the earphone electronics 210. If the measured temperature is outside the expected range (i.e., too high or too low), a warning can be provided to the user in the form of an audible signal or a prompt displayed on an external electronic device 190.

[0102] During the process in box 2016, the pressure applied by the user to the curable filler material 801 can be monitored using a pressure sensing device (not shown) (e.g., a strain gauge) found in the I / O device 213 within the earphone electronics 210. If the measured pressure applied by the user is outside the expected range (i.e., too high or too low), a warning can be provided to the user in the form of an audible signal or a prompt displayed on an external electronic device 190.

[0103] Figure 9A A cross-sectional view is shown of a customizable earplug 102 according to one embodiment and certain components for adding a curable filler material 801 to the customizable earplug 102. For example, Figure 9A A syringe 901 is shown inserted into the internal volume 610 of the sleeve assembly 401. The syringe 901 can contain curable filler material 801. The syringe 901 can be inserted through a first tube 4231 of the sound tube assembly 403 and through a first hole 921 extending through the support spacer 402 and the flexible PCB 217. A vacuum tube 902 can be connected to a second tube 4232 of the sound tube assembly 403. The second tube 4232 can be connected to the internal volume 610 of the sleeve assembly 401 through the support spacer 402 and the second hole 922 of the flexible PCB 217. The vacuum tube 902 can be connected to a vacuum pump (not shown) to provide suction to the internal volume 610 through the second tube 4232 and the second hole 922. The suction helps to distribute the curable filler material 801 throughout the internal volume 610 of the sleeve assembly 401. After the curable filler material 801 is added to the internal volume 610 of the sleeve assembly 401, the tube 423 can be cut and sealed so that the curable filler material 801 is contained in the internal volume 610 of the sleeve assembly 401.

[0104] Figure 9BA cross-sectional view is shown of a customizable earplug 103 according to one embodiment and certain components for adding a curable filler material 801 to the customizable earplug 103. The customizable earplug 103 is identical to the customizable earplug 102, except that the customizable earplug 103 includes a flat tube extending through a sound tube assembly 403, a support spacer 402, and a flexible PCB 217, instead of... Figure 9A The customizable earbud 102 shown includes a tube 423 and holes 921, 922. The customizable earbud 103 includes a first flat tube 941 and a second flat tube 942, each extending through holes in the sound tube assembly 403, the support spacer 402, and the flexible PCB 217 to connect the internal volume 610 of the sleeve assembly 401 to the external environment. The support portion 404 may include a first hole 951 and a second hole 952 respectively aligned with the first flat tube 941 and the second flat tube 942.

[0105] The first flat tube 941 can be used to add curable filler material 801 into the internal volume 610 of the sleeve assembly 401. The second flat tube 942 can be used to apply suction through the second flat tube 942 to the internal volume 610 of the sleeve assembly to assist in distributing the curable filler material 801 throughout the internal 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 a flexible, compressible material that allows the flat tubes 941, 942 to expand as the curable filler material 801 is added through the first flat tube 941 and suction is applied through the second flat tube 942 to the internal volume 610. In one embodiment, a balloon catheter can be used to expand the flat tubes 941, 942 during the addition of the curable filler material 801 into the internal volume 610.

[0106] Figure 9C An example of an implementation that has been used for expansion is shown. Figure 9B The first flat tube 941 and the balloon catheter 960. Figure 9C After the balloon catheter dilates the first flat tube 941, in Figure 9B An enlarged view of region 9C is shown. The balloon catheter 960 includes a pointed tip 966 to facilitate insertion of the balloon catheter 960 into the first flat tube 941. The balloon catheter 960 also includes a central channel 965 and one or more balloons 962. In one embodiment, the first balloon catheter 960 is used to dilate the first flat tube 941 and the second balloon catheter 960 is used to dilate the second flat tube 942. When the first flat tube 941 is dilated, the central channel 965 of the first balloon catheter 960 can be used to insert a syringe, for example... Figure 9AThe syringe 901 is used to add curable filler material 801 into the internal volume 610 of the sleeve assembly 401. When the second flat tube 942 is expanded, the central channel 965 of the second balloon catheter 960 can be used to connect the vacuum tube, and... Figure 9A Similar to the vacuum tube 902, suction can be applied to the internal volume 610 to assist in distributing the curable filler material 801 throughout the internal volume 610 of the sleeve assembly 401. After the curable filler material 801 is added to the internal volume 610 of the sleeve assembly 401, the balloon catheter 960 can be removed from the flat tubes 941, 942, which restores the flat tubes 941, 942 to their original position. Figure 9B The flat state is shown in the figure. After the balloon catheter 960 is removed, the compression of the flat tubes 941, 942 by components such as the support spacer 402 and the sound tube assembly 403 is sufficient to seal the flat tubes 941, 942, so that no separate sealing step is required to accommodate the curable filler material 801 in the internal volume 610 of the sleeve assembly 401.

[0107] Figure 10 This is a process flow diagram of method 3000 for manufacturing customizable earplugs 102 and customizable earplugs 103. Although the method steps are described with reference to the systems and components shown in Figures 1-9C, those skilled in the art will understand that any system configured to perform the method steps in any order is within the scope of this disclosure provided herein.

[0108] Referring to Figure 1-9C, method 3000 is described. In block 3002, a sleeve 600 is formed. The sleeve 600 can be formed using various molding processes, such as compression molding, injection molding, and dip molding. In block 3004, the sleeve 600 can be flipped from the inside out, and the inner surface of the sleeve (i.e., the surface facing outwards after the sleeve 600 is flipped from the inside out) can be covered by an inner coating 601. The inner coating 601 can be applied to the sleeve 600 using spray coating, spin coating, or physical vapor deposition.

[0109] At block 3006, the sound tube assembly 403 may be formed. The sound tube assembly 403 may be formed using various molding processes, such as compression molding, injection molding, and dip molding. At block 3008, the sound tube assembly 403 may optionally be covered by a reflective outer coating 602. In some embodiments, the sound tube 422 may contain a reflective material, and therefore the reflective outer coating 602 may be omitted.

[0110] In frame 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. In frame 3012, the sound tube assembly 403 can be attached to the sleeve assembly 401. For example, in one embodiment, a retaining ring 615 can be used to secure the sound tube 422 to the inward protrusion 622 of the sleeve assembly 401.

[0111] In an alternative embodiment, the sound tube assembly 403 may first be formed using the molding process described for frame 3006, and then the sleeve assembly 401 may be overmolded onto the sound tube assembly 403. For example, in one embodiment, the sleeve assembly 401 may be overmolded onto the sound tube assembly 403 such that the sleeve assembly 401 is formed from the inside out and is attached to the end of the sound tube assembly 403 near the sound tube 422, for example, around which a retaining ring 615 is attached. Figure 6 The area shown in the figure. In some embodiments where the sleeve assembly 401 is overlap-molded onto the sound tube assembly 403, the retaining ring 615 may be omitted. After the sleeve assembly 401 is overlap-molded onto the sound tube assembly 403 from the inside out, the inner side of the sleeve assembly 401 and the outer side of the sound tube assembly 403 may be simultaneously covered with separate reflective coatings. After covering the sleeve assembly 401 and the sound tube assembly 403, frame 3010 may be formed so that 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.

[0112] In frame 3014, the sleeve assembly 401 is flipped from the inside out and extends around the base 421 of the sound tube assembly 403, such that the tube 423 of the sound tube assembly 403 can extend through the collar 411 of the sleeve assembly 401. In frame 3016, the support 404 can be attached to the sound tube assembly 403, for example, by using fasteners that extend through the support 404, the collar 411 of the sleeve assembly 401, and into the base 421 of the sound tube assembly 403.

[0113] In frame 3018, curable filler material 801 can be added to the internal volume 610 of sleeve assembly 401. For customizable ear tips 102 (see...) Figure 9A A curable filler material 801 can be added, for example, by inserting a syringe 901 into one of the tubes 423 and attaching a vacuum tube 902 to the other of the tubes 423, as referenced above. Figure 9A Described.

[0114] In one implementation, an alternative configuration for the customizable earbud 103 (see...) Figure 9BThe conduit 960 can be inserted into each of the flat tubes 941 and 942, such that a syringe can be inserted into the first flat tube 941 for adding the curable filler material 801, and a vacuum tube can be attached to the second flat tube 942 to help distribute the curable filler material 801 throughout the internal volume 610, as referenced above. Figure 9B and 9C Described. In box 320, after the curable filler material 801 is added to the internal volume 610, the opening for tube 423 can be sealed. In one embodiment, a TPU plug can be inserted into tube 423 and then the tube can be clamped using a heated shear, which enables any remaining openings to be welded closed. Customizable earplug 103 (see...) Figure 9B No separate sealing step is required because the compression of the flat tubes 941, 942 by components such as the support spacer 402 and the sound tube assembly 403 is sufficient to seal the flat tubes 941, 942 when the conduit 960 is removed.

[0115] Figure 11 A cross-sectional view of a customizable earplug 1102 after a curable filler 801 has been incorporated into the customizable earplug 1102, according to one embodiment, is shown. The customizable earplug 1102 is similar to the customizable earplug 102 described above, except that the customizable earplug 1102 includes an optical fiber cable 1105 extending from one of the radiation sources 215 to the ear tip 412 of the sleeve assembly 401. The optical fiber cable may be embedded in the curable filler material 801. The optical fiber cable 1105 may be secured to the sound tube 422, for example, by using one or more retaining rings 1106. In one embodiment, the one or more retaining rings are resilient rings. The optical fiber cable 1105 may include an end 1107 positioned in the ear tip 412 of the customizable earplug 1102 for directly emitting light into the curable filler material 801 located in the ear tip 412. Directly emitting light into the curable filler material 801 can increase the curing rate of the curable filler material 801 located at the ear tip 412 and can also promote more complete curing of the curable filler material 801 located at the ear tip 412. In contrast, the customizable earplug 102 only emits light from the radiation source 215 into the curable filler material 801 located near the base 421 of the sound tube assembly 403.

[0116] The customizable earbud 1102 includes one or more radiation sources 215 not connected to an optical fiber cable. These radiation sources 215 direct light from some of the same locations described above for the customizable earbud 1102, near the base 421 of the sound tube assembly 403, into a curable filler material. Furthermore, although only one optical fiber cable 1105 is connected... Figure 11As shown, however, the customizable earplug 1102 may include two or more fiber optic cables 1105 connected to the radiation source 215. These fiber optic cables 1105 may extend to different locations within the sleeve assembly 401 to further balance the distribution of light during the curing of the curable filler material 801. By emitting some light from one or more radiation sources 215 near the base 421 of the sound tube assembly 403 and emitting some light from the ends of the fiber optic cables located at various locations within the sleeve assembly 401, such as at the ear tip, the curable filler material 801 at different locations within the sleeve assembly 401 can be exposed to light in a more similar manner, which can promote curing of the curable filler material 801 at these different locations at a more uniform rate than for the customizable earplug 102 described above. By reducing the variability in the curing rate of the curable filler material 801 at different locations within the sleeve assembly 401, the mechanical stress caused by different curing rates can be reduced. These mechanical stresses can interfere with the bonding between the curable filler material 801 and the sleeve assembly 401 and ultimately reduce the reliability and lifespan of the customizable earplugs. Therefore, by using one or more fiber optic cables 1105 to distribute light from the radiation source 215 to different locations within the sleeve assembly, such as in the ear tip 412, the reliability and lifespan of the customizable earplugs 1102 can be improved.

[0117] Figure 12 A cross-sectional view of a customizable earplug 1202 after a curable filler material 801 has been added, according to one embodiment, is shown. The customizable earplug 1202 is similar to the customizable earplug 102 described above, except that the customizable earplug 1202 includes an optical fiber cable 1205 extending from a support 404 to an ear tip 412 within a sleeve assembly 401. The optical fiber cable 1205 may be embedded in the sleeve assembly 401 between a sleeve 600 and an inner cladding 601. The optical fiber cable 1205 may include an end 1207 positioned in the ear tip 412 of the customizable earplug 1202 for directly emitting light into the curable filler material 801 located in the ear tip 412. Directly emitting light into the curable filler material 801 can increase the curing rate of the curable filler material 801 located in the ear tip 412 and can also promote more complete curing of the curable filler material 801 located in the ear tip 412. Compared with the customizable earplug 102, the customizable earplug 102 only emits light from the radiation source 215 into the curable filler material 801 located near the base 421 of the sound tube assembly 403.

[0118] In some embodiments, fiber optic cable 1205 can be connected to an external LED 1210. Fiber optic cable 1211 can transmit light from the external LED to fiber optic cable 1205, which in turn transmits the light to the curable filler material 801 in the sleeve assembly 401. Fiber optic coupler 1215 can be used to couple fiber optic cable 1211 to fiber optic cable 1205. Fiber optic cable 1205 can be used to promote more complete curing of the curable filler material in the ear tip 412 and to balance the curing rate of the curable filler material 801 in the ear tip 412 with that in other locations in the sleeve assembly 401, in accordance with the above reference. Figure 11 Similar to the method described in Fiber Optic Cable 1105.

[0119] In some embodiments where an external LED is used to transmit light into the sleeve assembly 401 via fiber optic cables, the radiation source 215, flexible PCB 217, and support spacer 402 may be omitted. In some of these embodiments, more than one fiber optic cable or a fiber optic cable with multiple branches may be used to transmit light to different locations within the sleeve assembly 401 to balance the curing rate of the curable filler material 801 at different locations relative to each other, thereby reducing mechanical stress caused by variations in the curing rate, as referenced above. Figure 11 Described.

[0120] Figure 13 A cross-sectional view of a customizable earplug 1302 before curable filler material 801 has been added, according to one embodiment, is shown. The customizable earplug 1302 is similar to the customizable earplug 102 described above, except that the customizable earplug 1302 includes a sound tube assembly 1303, instead of the sound tube assembly 403 included in the customizable earplug 102. The sound tube assembly 1303 includes a translucent sound tube 1320. The translucent sound tube 1320 may be translucent to energy emitted by the radiation source 215, for example, translucent to light with a wavelength of 405 nm. The translucent sound tube 1320 may be partially covered by the reflective outer coating 602 described above. The reflective outer coating 602 may be opaque to energy emitted by the radiation source 215.

[0121] The sound tube 1320 may include a first portion 1321 and a second portion 1322 not covered by the outer cover 602. The first portion 1321 may be located near one of the radiation sources 215. The second portion 1322 may be located in the ear tip 412 of the sleeve assembly 401. Light L from the radiation source 215 near the first portion 1321 may be transmitted into the sound tube 1320, and the light L may then be transmitted from the sound tube 1320 by the second portion 1322 to a curable filler material (not shown) located in the ear tip 412. In some embodiments, an opaque reflective cap 1330 may be placed on the ear tip 412 such that the light L in the sound tube 1320 is not directed at the user. This opaque reflective cap 1330 may be particularly important if the radiation source 215 emits UV energy, as exposure to UV energy should be avoided. The fiber optic cable 1205 may include an end 1207 positioned in the ear tip 412 of a customizable earplug 1202 for directly emitting light into a curable filler material 801 located in the ear tip 412. Emitting light through a second portion 1322 of the sound tube 1320 into the curable filler material 801 in the ear tip 412 can increase the curing rate of the curable filler material 801 in the ear tip 412 and also promote more complete curing of the curable filler material 801 in the ear tip 412, compared to the customizable earplug 102, which only emits light from the radiation source 215 into the curable filler material 801 located near the base 421 of the sound tube assembly 403.

[0122] In another embodiment, a sound tube assembly including varying translucency can be used to further balance the distribution of light to the curable filler material during the custom process. For example, in one embodiment, a translucent sound tube assembly can be formed, and then different portions of the sound tube can be covered with varying amounts of opaque or semi-translucent coatings, such that the translucency of the sound tube gradually varies along its length. The sound tube assembly may still include a more fully translucent portion adjacent to the radiation source 215, similar to the first portion 1321 described above. In such an embodiment, the translucency of the sound tube (excluding the more fully translucent portion adjacent to the radiation source 215) may gradually increase as the sound tube extends toward the ear tip 412. The ear tip 412 may also include a more fully translucent portion similar to the second portion 1322 described above. This gradual variation in the translucency of the sound tube helps balance the light emitted onto different portions of the curable filler material, allowing for a more uniform curing rate across the different portions.

[0123] Figure 14AIt is a cross-sectional view of the customizable earplug 102 before the curable filler material 801 has been added to the customizable earplug 102 according to at least one embodiment. Figure 14B yes Figure 14A A close-up cross-sectional view of a portion. In conventional devices, the curable filler material 801 cannot easily travel or flow from the end of the audio component 111 of the customizable earbud 102 through the internal volume 610, as referenced above. Figures 9A-9C The discussion extends to the opposite end of the ear tip portion 412, leaving a partially filled area or gap near the ear tip portion 412. An unfilled ear tip portion 412 can result in the inability to control or maintain the shape of the ear tip portion 412 after the curing process has been performed, which can lead to variability in the degree of fit of the customizable earplug 102 in the user's ear and / or discomfort for the user. However, in these embodiments, the curable filler material 801 is injected into the internal volume 610 of the ear tip portion 412 of the customizable earplug 102. More specifically, a tube 1401 can be inserted between the sleeve assembly 401 and the sound tube 422, as in... Figure 14B As shown in the diagram. The curable filler material 801 can then be inserted into the ear tip portion 412, resulting in an increase in the capacity of the filler volume 610, typically the portion inserted into the user's ear. Accordingly, proper filling of the volume 610 and subsequent curing of the curable filler material 801 in the ear tip portion 412 ensure that the customizable earplug 102 will fit comfortably and reliably in the same manner each time it is inserted into the user's ear.

[0124] During the manufacturing process, in one embodiment, a filling device 1410, including a tube 1401 connected to a curable filler material source 1405, injects a curable filler material 801 into the ear tip portion 412. Prior to injection, the curable filler material 801 is contained within the curable filler material source 1405, which is fluidly connected to the tube 1401. The tube 1401 is then inserted through the ear tip portion 412 of the earplug 102. Due to pressure applied to the curable filler material 801 from a pressure control device (e.g., a gas source, a manually compressible component) in the curable filler material source 1405, the curable filler material 801 flows through the tube 1401 into the area where the tube 1401 is inserted, which has an internal volume of 610. In some embodiments, the tube 1401 may have a valve 1407 and an actuator 1408. Valve 1407 can be used to selectively apply curable filler material 801 from curable filler material source 1405 into internal volume 610, and optionally, actuator 1408 can be used to draw air out of internal volume 610 by pumping action.

[0125] Figure 14C This is a cross-sectional view of a customizable earplug 102 before the curable filler material 801 has been added to the customizable earplug 102, according to at least one embodiment. In these embodiments, a needle 1402 is used in combination with a tube 1401 to better control the insertion of the curable filler material 801 and to minimize the chance of piercing the sleeve 600 of the sleeve assembly 401 by using the flexible needle 1402. The needle 1402 can be a flexible needle containing a pre-formed deformable material, such as nickel-titanium. The needle 1402 can be pre-formed such that, in its normal state, for example before insertion into the tube 1401, the needle 1402 has a shape in which it has folds. In this case, the needle 1402 is configured to be positioned within the inner diameter of the tube 1401 and further configured to slide within the tube 1401. The tube 1401 is adapted to hold the needle 1402 in an unbent or straight configuration until the needle 1402 passes a point in the tube 1401 that extends beyond the outlet end of the tube 1401, thus allowing the needle 1402 to bend and return to its undeformed shape. While the needle 1402 is in the retracted position within the tube 1401, the needle 1402 is held straight. In other embodiments, such as in... Figure 14C As best shown, the needle 1402 extends forward from the tube 1401, causing it to bend and return to its pre-formed shape. The pre-formed bend in the needle 1402 can then be positioned and oriented by the user such that the outlet 1426 of the needle 1402 is oriented toward the end of the internal volume 610 near the ear tip portion 412. In some cases, the outlet 1426 of the needle 1402 may be oriented parallel to the sidewall of the sound tube 422 or a portion of the sleeve 600 near the ear tip portion 410 to prevent the end portion of the needle 1402 near the outlet 1426 from piercing the sound tube 422 or the sleeve 600. (See also...) Figure 14C As shown, needle 1402 has a first portion 1422 and a second portion 1421. The first portion 1422 is substantially parallel to direction 1415, which is substantially parallel to the sidewall of tube 1401. The first portion 1422 of needle 1402 is held in this orientation by the sidewall of tube 1401, preventing the first portion 1422 from bending into the pre-formed shape of needle 1402. The second portion 1421 is substantially parallel to direction 1423, which is substantially parallel to the sidewall of sound tube 422. The second portion 1421 of needle 1402 is not held in place by the sidewall of tube 1401 and is therefore bent into its pre-formed shape. Accordingly, needle 1402 is bent at an angle 1424 between direction 1415 and direction 1423, preventing the end of outlet 1426 of needle 1402 from piercing sound tube 422 and sleeve 600. Instead, the outlet 1426 of needle 1402 is located in the center facing the internal volume 610.

[0126] Furthermore, in some embodiments, barrier 1430A ( Figure 14A Barriers 1430A and 1430B are located within the internal volume 610 to prevent the tip portion of needle 1402 from piercing sleeve assembly 401 at outlet 1426 when the curable filler material 801 is inserted into the internal volume 610 and when air is drawn out from the internal volume 610. More specifically, barrier 1430A prevents the tip portion of needle 1402 from piercing sleeve 600 of sleeve assembly 401, and barrier 1430B prevents the tip portion of needle 1402 from piercing inward protrusion 622 of sleeve assembly 401. Barriers 1430A and 1430B may also include geometric features to prevent sleeve assembly 401 from collapsing onto needle 1402, and may include a portion of a flexible and puncture-resistant material, such as an elastomer or plastic material (e.g., natural rubber, polyethylene sheet, polyester film sheet).

[0127] In other implementations, such as in Figure 14E As shown, instead of inserting the tube 1401 through the sleeve assembly 401 to inject the curable filler material 801 near the ear tip 412 into the internal volume 610, the inward protrusion 622 of the sleeve assembly 401 can be folded upward from its sealed position at the output area 426 above the sound tube 422 to an open position, creating a space 1470 between the sleeve assembly 401 and the sound tube 422. The curable filler material 801 can then be inserted into the internal volume 610 through the space 1470 formed near the ear tip 412 by the curable filler material source 1405, without having to insert the tube 1401 through the sleeve assembly 401. After the curable filler material 801 is inserted into the internal volume 610, the inward protrusion 622 of the sleeve assembly 401 can be folded upward from its open position (i.e., above the sound tube 422) at the output area 426 of the sound tube 422. Figure 14E ) Fold back to its sealed position (i.e. Figure 7 When in the open position, the sound tube 422 can be protected by the cap 1471, so that the curable filler material 801 does not flow within the sound tube 422.

[0128] In another implementation, such as in Figure 14D As shown, tube 1401 is inserted into customizable earplug 102 such that it pierces sound tube 422 and thus allows needle 1402 to be positioned within internal volume 610. Similarly, in... Figure 14C As described, the needle 1402 is held in its retracted position by the tube 1401 and then bends into its pre-formed shape as it extends forward to a desired position past the outlet of the tube 1401. Used with... Figure 14CThe needle 1402 has a similar construction to the tube 1401, with the needle 1402 configured to bend so that it conforms to the contour of the sound tube 422 without piercing the sleeve 600. In some embodiments, the sound tube 422 is made of a self-sealing material (e.g., a soft-hard material) to prevent subsequent leakage of the injected curable filler material 801 when the tube 1401 and needle 1402 are removed.

[0129] Figure 15A It is a cross-sectional view of an optional configuration of a customizable earplug 102 after a curable filler material 801 has been added to the customizable earplug 102 according to at least one embodiment. Figure 15B yes Figure 15A A close-up cross-sectional view of a portion. Figure 15A The structure shown in the diagram is as follows: Figure 6 The implementation shown is similar, except that the radiation source 215 is located outside the internal volume 610 and within the housing of the audio component 111. (As shown in...) Figures 15A-15B As shown, the radiation source 215 is detachably coupled to a connector 405 and a cover 111C disposed at the end of the audio assembly 111. In some embodiments, the radiation source 215 is an LED configured to emit light of one or more wavelengths capable of curing a curable filler material 801.

[0130] In some implementations, the LED is positioned to output light (in Figure 15A As shown in the diagram (L), light travels through the internal volume 610 and the permeable sound tube 422 to cure all the curable filler material 801 after it has been injected into and filled the internal volume 610. Figure 15B As shown, the radiation source 215 is located outside the internal volume 610 and adjacent to the surface of a portion of the sleeve 600, which does not include the light-reflective inner cladding 601 or a large amount of light-reflective material disposed within the material used to form the sleeve 600. Therefore, the output light from the radiation source 215 will travel through the unclad portion of the sleeve 600 and enter the internal volume 610 to effectively cure the curable filler material 801. In this embodiment, the portion of the sleeve 600 and the sound tube 422, i.e., the output light L( Figure 15A The portion of the curable filler material 801 that needs to be traveled through to fully cure it must be optically permeable to radiation emitted by the radiation source 215 at the wavelength used to cure the curable filler material 801. In some configurations of the earplug 102, the outer cladding 602 is not deposited on the sound tube 422 and the inner cladding 601 is not deposited on a portion of the sleeve 600, and at least a portion of the sound tube 403 and the sleeve 600 are made of a material permeable to light emitted from the radiation source 215 at one or more wavelengths.

[0131] Also there Figure 15B As shown, one or more optical lenses 1510 may be incorporated into the earphone assembly 101. Each optical lens 1510 may be positioned adjacent to the radiation source 215 such that the lens or a portion thereof can more uniformly disperse the emitted radiation throughout the internal volume 610, resulting in more uniform curing of the curable filler material 801. The one or more optical lenses 1510 may be Fresnel lenses, spherical lenses, or other types of lenses that are intended to guide and disperse the radiation emitted by the radiation source 215.

[0132] Figure 16 This is a cross-sectional view of the customizable earplug 102 before the curable filler material 801 has been added to the customizable earplug 102, according to at least one embodiment. In these embodiments, the sleeve 600 can self-seal after the curable filler material 801 is injected into the internal volume 610. (As in...) Figure 16 As shown in and as described above Figures 14A-14C As described, a curable filler material 801 is injected into a tube 1401. Prior to injection, the curable filler material 801 is contained within a curable filler material source 1405 fluidly connected to the tube 1401. The tube 1401 is then inserted through a sleeve of an earpiece 102. However, in these embodiments, the sleeve 600 contains a region 1440, where the tube 1401 is inserted. Region 1440 is thicker than any other region of the sleeve 600, and is thus configured to significantly constrain the flow of the curable filler material 801 from the internal volume 610 to the external region 1601 after the internal volume 610 has been filled using the filling device 1410. The thickness of region 1440 allows the sleeve 600 to self-seal after the tube 1401 is pulled out of the internal volume 610. Furthermore, region 1440 may also include a pre-formed slit designed to self-seal after the tube 1401 is removed from the internal volume 610.

[0133] Figure 17 It is according to at least one embodiment along in Figure 6 The cross-sectional view of the customizable earplug 102, taken by section line 17-17, is shown in the figure. To prevent undesirable collapse and / or folding of portions of the sleeve 600 when pressure is applied by the user during insertion of the earplug 102 into the user's ear, in some embodiments, the sleeve assembly 401 is designed to have ribs or shaped contours within it configured to control bending or deformation of portions of the sleeve 600. The ribs or shaped contours within the sleeve assembly 401 can be formed and configured to prevent unwanted bending or deformation based on the general shape of most users' ears for the majority of the population. As shown in... Figure 17As shown, the contoured segments or ribs include alternating inner segments 1710 and outer segments 1711, thereby creating contoured segments or ribs extending from the auricular portion 412 to the opposite end 413 within the sleeve assembly 401. The contoured segments or ribs may optionally or additionally be aligned in an angle (e.g., vertical) relative to the direction of extension from the auricular portion 412 to the opposite end 413 (e.g., the "loop" direction in the auricular portion). The contoured segments or ribs can help control the bending stiffness of the sleeve assembly 401 in different areas of the sleeve assembly 401, or can eliminate collapse in certain areas of the sleeve assembly 401.

[0134] In other embodiments, the sleeve assembly 401 is configured to include different thicknesses in different areas of the sleeve 600 of the sleeve body. Controlling the different thicknesses of the sleeve 600 also helps prevent or eliminate collapse of the sleeve assembly 401 during its insertion into the user's ear. For example, as in... Figure 6 As shown, the sleeve 600 includes a first zone 691 and a second zone 692. The first zone 691 may be thicker than the second zone 692 by some amount; for example, the first zone 691 may be twice as thick as the second zone 692. In one embodiment, the thickness of the first zone 691 may be about 0.3 mm and the thickness of the second zone 692 may be about 0.15 mm; however, these thicknesses can vary. Controlling the thickness in the different zones of the sleeve 600 helps control the amount of compression within different portions of the sleeve, which then directs the flow of curable filler material into the different zones of the sleeve 600 when pressure is applied to it, for example, when a user pushes the sleeve 600 against the inside of a user's ear. The thickness of the sleeve 600 may be controlled or created during one or more periods of the process described in block 3002 of method 3000. For example, when the user applies pressure, the thicker first zone 691 may not deflect as much as the thinner second zone 692. Accordingly, the second zone 692 will receive more curable filler material 801 under applied pressure due to its greater flexibility, which can result in better support in the user's ear. Furthermore, in these embodiments, controlling the thickness of the sleeve 600 improves the overall retention and comfort of the earplug 102. In some embodiments, the transition between the first zone 691 and the second zone 692 is gradual. However, the transition can also be more abrupt.

[0135] In some implementations, reference Figure 1B and Figure 6The second region 692 is defined by a portion of the sleeve assembly 401 positioned to adhere to the surface of the ear canal 2, and the first region 691 is defined by a portion of the sleeve assembly 401 positioned to adhere to the surface of the concha 3 and the cymba concha 4. The transition between the first region 691 and the second region 692 can be located at the entrance to the ear canal 2 and the central portion of the concha 3, or located between the entrance to the ear canal 2 and the central portion of the concha 3. In some embodiments, a portion of the second region 692 extends beyond the helix crus 5 to allow some compliance in this region of the body portion 415 of the sleeve assembly 401, and thus allows this region of the body portion 415 to comply with at least the surface of the helix crus 5. Furthermore, a portion of the second region 692 can be located in regions corresponding to the tragus 10, the antitragus 12, and the intertragus notch (not shown) to improve flexibility or compliance in these regions.

[0136] While the foregoing relates to embodiments of this disclosure, other and further embodiments of this disclosure may be contemplated without departing from its basic scope, which is defined by the claims below.

Claims

1. An audio device comprising an earbud-type headphone assembly, including: Earplugs, including: The main body has an inner surface and is formed of a flexible material; A sound tube, connected to the housing body, wherein the inner surface of the housing body and the outer surface of the sound tube at least partially define the internal volume of the earplug, wherein the housing body is overlap-molded onto the sound tube such that the housing body is attached to an end of the sound tube; and Curable filler material, arranged within the internal volume; and One or more radiation sources are positioned to emit light of one or more wavelengths through a portion of the housing and into the curable filler material disposed within the internal volume, wherein the curable filler material is configured to be cured by the emitted light of the one or more wavelengths; and Audio components, including: An audio driver configured to transmit audible sound to the inner surface of the sound tube, and The audio component is detachably connected to the earpiece via a connector that connects the earpiece to the audio component at a connection point disposed on the audio component, and the connector is used to provide an electrical connection to the radiation source.

2. The audio device of claim 1, wherein the housing body includes a reflective coating disposed on the inner surface of the housing body.

3. The audio device of claim 1 further includes a portable power supply configured to power the audio driver and the radiation source.

4. The audio device according to claim 3, wherein the audio component further comprises: A processor, coupled to a memory, wherein the memory includes instructions configured, when executed by the processor, to perform methods including: The portable power source supplies power to the radiation source for a continuous first time period.

5. The audio device of claim 1, wherein the main body further comprises a main body portion disposed between an ear tip portion and a fin portion, the ear tip portion being configured to be inserted into the ear canal of a user's ear, and the fin portion being configured to be positioned in close contact with the concha of the user's ear.

6. The audio device of claim 1, wherein the audio device further comprises at least one additional radiation source disposed within the internal volume of the earpiece, and the at least one additional radiation source being spaced apart from each other within the internal volume.

7. The audio device of claim 6, wherein the radiation source and the at least one additional radiation source are arranged on a flexible printed circuit board.

8. The audio device of claim 1, wherein the audio component further comprises: A housing that surrounds the audio driver, wherein a portion of the housing is configured to be disposed within an opening formed in the earpiece, the opening being positioned adjacent to the input area of ​​the sound tube.

9. The audio device according to claim 1, wherein the audio device further comprises: The controller component includes one or more electrical components that communicate with the audio driver of the audio component; and The audio component also includes a housing surrounding the audio driver, wherein the controller component is connected to the housing via a cable.

10. The audio device according to claim 1, further comprising: Housing that surrounds the audio driver; as well as A portable power supply configured to power the audio driver and the radiation source, wherein the portable power supply is connected to the housing via a cable.

11. The audio device of claim 1, wherein the sleeve body further comprises one or more ribs formed on the inner surface of the sleeve of the sleeve body.

12. The audio device of claim 1, wherein the sleeve body further comprises a body portion and an ear tip portion, wherein the sleeve body has a first thickness within the ear tip portion and a second thickness within the body portion, the second thickness being different from the first thickness.

13. The audio device of claim 1, wherein the audio component further comprises: A housing surrounds the audio driver, and The radiation source is arranged inside the housing.

14. The audio device of claim 1, further comprising one or more optical lenses positioned adjacent to each of the one or more radiation sources, the one or more optical lenses being configured to disperse light of the one or more wavelengths through the internal volume.

15. An audio device, comprising: Two in-ear headphone assemblies, each including an earbud, an audio component, and one or more radiation sources, wherein each of the earbuds includes: The main body has an inner surface and is formed of a flexible material; A sound tube, connected to the housing body, wherein the inner surface of the housing body and the outer surface of the sound tube at least partially define the internal volume of the earplug, wherein the housing body is overlap-molded onto the sound tube such that the housing body is attached to an end of the sound tube; and A curable filler material is arranged within the internal volume; The one or more radiation sources are positioned to emit light of one or more wavelengths through a portion of the housing and into the curable filler material disposed within the internal volume, wherein the curable filler material is configured to be cured by the emitted light of the one or more wavelengths. The audio component includes: An audio driver configured to transmit audible sound to the inner surface of the sound tube. The outer surface of the housing of the first of the two earbud-type headphone assemblies has a shape different from the outer surface of the housing of the second of the two earbud-type headphone assemblies. Each of the earbuds further includes a connector that detachably connects the earbud to the audio component at a connection point on the audio component, the connector being used to provide an electrical connection to the radiation source.

16. The audio device of claim 15, wherein the audio component further comprises a portable power supply configured to power the audio driver and the radiation source.

17. The audio device of claim 16, wherein the audio device further comprises: The controller assembly includes one or more electrical components that communicate with the audio driver, and The audio component within each of the two in-ear headphone assemblies also includes a housing surrounding the audio driver. The controller component is connected to the housing via a cable.

18. The audio device of claim 15, wherein each of the housing bodies further comprises a body portion disposed between an ear tip portion and a fin portion, the ear tip portion being configured to be inserted into the ear canal of a user's ear, and the fin portion being configured to be positioned against the concha of the user's ear.

19. The audio device of claim 18, wherein the shape of the body of the first and second of the two earbud-type headphone assemblies is a mirror image of each other before the curable filler material is cured by the radiation source.

20. The audio device of claim 15, wherein each of the earbuds further comprises at least one additional radiation source disposed within the internal volume, and the at least one additional radiation source in each of the earbuds is spaced apart from each other within the internal volume.

21. The audio device of claim 15, wherein the audio component within each of the two in-ear headphone assemblies further comprises: A housing surrounds the audio driver, and The radiation source is arranged inside the housing.

22. The audio device of claim 15, wherein the audio component within each of the two in-ear headphone assemblies further comprises: A housing that surrounds the audio driver, wherein a portion of the housing is configured to be disposed within an opening formed in the earpiece, the opening being positioned adjacent to the input area of ​​the sound tube.

23. The audio device of claim 15, wherein the audio component further comprises: A portable power supply configured to power the audio driver and the radiation source; as well as A processor, coupled to a memory, wherein the memory includes instructions configured, when executed by the processor, to perform methods including: The portable power source supplies power to the radiation source for a continuous first time period.

24. The audio device of claim 15, wherein each of the housing bodies further comprises a body portion and an ear tip portion, wherein each of the housing bodies has a first thickness within the ear tip portion and a second thickness within the body portion, the second thickness being different from the first thickness.

25. The audio device of claim 15, further comprising one or more optical lenses positioned adjacent to each of the one or more radiation sources, the one or more optical lenses being configured to disperse light of the one or more wavelengths through the internal volume.

26. The audio device of claim 15, wherein the audio device further comprises: The controller assembly includes one or more electrical components that communicate with the audio driver; as well as A portable power supply is disposed within the controller assembly, the portable power supply being configured to power the audio driver and the radiation source, wherein the controller assembly is connected to the housing via a cable, the cable including one or more lines electrically connecting the audio driver within each of the audio components to the portable power supply.

27. An audio device, comprising: Two in-ear headphone assemblies, each comprising an earbud and an audio component, wherein each of the earbuds includes: The main body has an inner surface and is formed of a flexible material; A sound tube, connected to the housing body, wherein the inner surface of the housing body and the outer surface of the sound tube at least partially define the internal volume of the earplug, wherein the housing body is overlap-molded onto the sound tube such that the housing body is attached to an end of the sound tube; and A curable filler material is disposed within the internal volume, wherein the curable filler material is configured to be cured by light emitted by a radiation source at one or more wavelengths. The audio component includes: An audio driver configured to transmit audible sound to the inner surface of the sound tube; A portable power supply configured to power the audio driver and the radiation source; Housing, surrounding the audio driver; and The controller assembly includes one or more electrical components in communication with the audio driver, wherein: The controller assembly is connected to the housing via a cable. The outer surface of the housing of the first of the two earbud-type headphone assemblies has a shape different from the outer surface of the housing of the second of the two earbud-type headphone assemblies. The controller assembly is connected to the housing via a cable, and The portable power supply is disposed within the controller assembly, wherein the cable includes one or more lines that electrically connect the audio driver in each of the audio assemblies to the portable power supply; Each of the earbuds further includes a connector that detachably connects the earbud to the audio component at a connection point on the audio component, the connector being used to provide an electrical connection to the radiation source.

28. An audio device including an earbud-type headphone assembly, comprising: Earplugs, including: The main body has an inner surface and is formed of a flexible material; A sound tube, including an inner surface and an outer surface, is connected to the sleeve body, wherein... The inner surface of the sleeve body and the outer surface of the sound tube at least partially define the internal volume of the earplug, wherein the sleeve body is overlapped and molded onto the sound tube such that the sleeve body is attached to the end of the sound tube; A curable filler material is disposed within the internal volume, wherein the curable filler material is configured to be cured by light emitted from one or more wavelengths by one or more radiation sources; and The one or more radiation sources are positioned to emit light of the one or more wavelengths through a first portion of the sound tube and into a central region at least partially defined by the inner surface of the sound tube, and then through a second portion of the sound tube into the internal volume; and Audio components, including: An audio driver configured to transmit audible sound to the inner surface of the sound tube, and The audio component is detachably connected to the earpiece via a connector that connects the earpiece to the audio component at a connection point disposed on the audio component, and the connector is used to provide an electrical connection to the radiation source.

29. The audio device of claim 28, wherein the sound tube is made of a self-sealing material.

30. The audio device of claim 28, wherein the sleeve body includes a self-sealing region configured to be pierced by a tube and having a thickness greater than any other portion of the sleeve body.

31. The audio device of claim 28, further comprising an optical fiber cable having a first end and a second end, wherein the first end is configured to receive light of one or more wavelengths emitted by the radiation source, and the second end is configured to emit the light of one or more wavelengths received at the first end into the internal volume.

32. The audio device of claim 31, wherein the first end of the optical fiber cable is positioned outside the internal volume.

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