Flocked earplug tip and covering

Abstract

A flocked earplug tip for an in-ear headphone is provided that exhibits excellent grip and durability relative to conventional earplug tips. More specifically, the flocked earplug tip has at least one surface coated with flocked fibers, which can facilitate gripping and better retain the earplug tip within the ear canal of the user. The flocked earplug tip may be used as an alternative earplug tip of an in-ear headphone or as a cover for a hard earplug tip of an in-ear headphone.

Description

[0001] Related Applications

[0002] This application claims priority to U.S. Provisional Patent Application Serial No. 63 / 411,984, titled "Earbud Covers," filed on September 30, 2022, under 35 U.S.C. § 119(e), the entire content of which is incorporated herein by reference. Background of the Invention 1. Field of the Technology

[0003] The present disclosure generally relates to flocked earbud tips and covers for earphones. More specifically, the present disclosure generally relates to flocked replacement earbud tips and covers for in-ear earphones.

[0004] 2. Description of the Related Art

[0005] In-ear earphones have become increasingly common in today's market because they can be used for a large number of activities. However, users encounter many wearing problems involving in-ear earphones, especially when the user is engaged in physical exercise (e.g., running, walking, lifting, etc.). In addition, it is known that even common daily activities (e.g., eating) will dislodge in-ear earphones from the user's ear canal.

[0006] To address this problem, many manufacturers have provided alternative earbud tips made of memory foam or silicone for in-ear earphones in an attempt to provide more grip within the user's ear canal. Unfortunately, these tips and covers still have difficulty staying in the user's ear canal during physical activity. In addition, these new tips exhibit poor durability and, in the case of memory foam, poor water resistance.

[0007] Therefore, there is still a need for improved earbud tips and covers for in-ear earphones. Summary of the Invention

[0008] One or more embodiments of the present disclosure generally relate to a flocked earbud tip for an in-ear earphone. Generally, the flocked earbud tip includes a body having an outer surface and an inner surface, wherein the flocked earbud tip is configured to fit into a user's ear canal, and wherein the outer surface is at least partially coated with a plurality of flocked fibers.

[0009] One or more embodiments of the present disclosure generally relate to a flocked earbud tip for an in-ear headphone. Generally, the flocked earbud tip includes a body having an outer surface and an inner surface, and the flocked earbud tip is configured to fit into a user's ear canal. In addition, the outer surface is at least partially coated with a plurality of flocked fibers, wherein the flocked fibers have an average length of less than 0.7 mm and are formed of polyamide, polyester, regenerated cellulose, cotton, or a combination of two or more of polyamide, polyester, regenerated cellulose, and cotton. In addition, the body is formed of a material having a Shore A hardness of less than 50.

[0010] One or more embodiments of the present disclosure generally relate to a method for forming a flocked earbud tip for an in-ear headphone. Generally, the method includes: (a) providing an earbud tip configured to fit into a user's ear canal; (b) applying an adhesive to at least a portion of the surface of the earbud tip to thereby form an adhesive-coated earbud tip; and (c) flocking a plurality of fibers onto at least a portion of the adhesive-coated earbud tip to form a flocked earbud tip. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Embodiments of the present invention are described herein with reference to the following drawings, in which:

[0012] Figure 1 A flocked earbud tip according to an exemplary embodiment of the present disclosure is depicted;

[0013] Figure 2 There is provided Figure 1 a side view of an exemplary flocked earbud tip;

[0014] Figure 3 There is provided Figure 1 a top view of an exemplary flocked earbud tip;

[0015] Figure 4 There is provided Figure 1 a bottom view of an exemplary flocked earbud tip;

[0016] Figure 5 A flocked earbud tip cover according to an exemplary embodiment of the present disclosure is depicted;

[0017] Figure 6 There is provided Figure 5 a bottom view of an exemplary flocked earbud tip cover;

[0018] Figure 7 A flocked earbud tip cover according to an exemplary embodiment of the present disclosure is depicted; and

[0019] Figure 8 There is provided Figure 7 a bottom view of an exemplary flocked earbud tip cover. Detailed Implementation Modes

[0020] It has been found that flocked earplug tips can be formed by using short fiber flocked earplug tips and covers, and these flocked earplug tips exhibit superior properties compared to conventional earplug tips. More specifically, by applying flocked fibers onto the surface of an earplug tip (including a cover for the earplug tip), excellent flocked earplug tips with excellent performance characteristics and durability can be formed.

[0021] As discussed in more detail below, the method for producing a flocked earplug tip can involve: (a) providing an earplug tip configured to fit into a user's ear canal; (b) applying an adhesive onto at least a portion of the surface of the earplug tip, thereby forming an adhesive-covered earplug tip; and (c) flocking multiple fibers onto at least a portion of the adhesive-covered earplug tip, thereby forming a flocked earplug tip.

[0022] Generally, the flocked earplug tips of the present disclosure can be in the form of alternative earplug tips for in-ear headphones or earplug tip covers configured to fit onto existing hard earplugs of in-ear headphones. In an embodiment where the flocked earplug tip is used as an earplug tip replacement, the flocked earplug tip can be attached to an existing in-ear headphone by removing the original earplug tip from the in-ear headphone and directly attaching the flocked earplug tip to the in-ear headphone. In such an embodiment, the flocked earplug tip can have the same or a similar shape as the original earplug tip it replaces. Alternatively, in an embodiment where the flocked earplug tip is used as an earplug tip cover, the flocked earplug tip can be placed on the existing hard earplug tip of an in-ear headphone. Thus, this will allow the flocked earplug tip to be in direct contact with the user's ear canal during use.

[0023] Turning to the method for producing a flocked earplug tip, the method begins by providing an earplug tip base. The earplug tip base can be manufactured via injection molding and can be configured to be used as an alternative earplug tip or cover for an earplug-type headphone with a non-flexible hard tip.

[0024] Ideally, the earplug tip is made of a material that can be flocked and is compatible with the flocking adhesive. In addition, it is desirable that the material does not deform during the curing step of the flocking process. In one or more embodiments, the body of the earplug tip can be formed of a thermoplastic elastomer, a thermoplastic vulcanizate (e.g., EPDM particles in a PP matrix), or a combination thereof. In different embodiments, the body of the earplug tip can be formed of silicone, foam, latex, polyester (e.g., PET), polyurethane, polyolefin (e.g., PE or PP), elastomer (e.g., ABS), or a combination of two or more of them. In certain embodiments, the body of the earplug tip can be formed of silicone, foam, or latex.

[0025] Additionally or alternatively, in one or more embodiments, the body of the earbud tip may be formed of a material exhibiting a Shore A hardness of at least 5, 10, 15, 20, 25, or 30 and / or less than 100, 90, 80, 70, 60, 50, 45, or 40.

[0026] Prior to applying the adhesive to the earbud tip, the selected surface of the earbud tip to be flocked may optionally be pre-treated. This optional pre-treatment may render the treated surface of the earbud tip more receptive to flocking. In one or more embodiments, prior to applying the adhesive to the earbud tip, at least a portion of one or more surfaces of the earbud tip may be pre-treated. Exemplary pre-treatments may include, for example, plasma treatment, priming, burning, corona oxidation, sandblasting, scratching, or fluorination.

[0027] In certain embodiments, at least a portion of one or more surfaces of the earbud tip may be pre-treated with an undercoat. In such embodiments, at least one undercoat may be applied to at least a portion of one or more surfaces of the earbud tip. Generally, the undercoat roughens the surface of the earbud tip, rendering it more receptive to flocking. In various embodiments, the undercoat may include an organic solvent, such as a xylene-containing solvent. An exemplary undercoat is 459X from Parker Hannifan 459X.

[0028] Additionally or alternatively, prior to applying the adhesive, a spacer and / or masking application may be added to the earbud tip in order to maintain the integrity of the earbud tip and / or mask certain surfaces of the earbud tip that are not desired to be covered by flocking fibers during the flocking process. A spacer may be added to the earbud tip during flocking to maintain the integrity and structure of the earbud tip. Exemplary spacers may include, for example, disposable foam, cover decoration, cover foam, or any other material known in the art that may maintain the integrity of the earbud tip during the flocking process.

[0029] A masking application (e.g., masking tape) may be used to control the application of flocking fibers to the outer and inner surfaces of the earbud tip. This may prevent the application of flocking fibers to certain surfaces of the earbud tip that may come into contact with certain sensitive areas within the user's ear canal. For example, a masking application may be applied to the outer surface in the area near the beginning of the inner tube to avoid applying flocking fibers to the very tip of the earbud tip.

[0030] After an optional pre-treatment, an optional spacer step, and / or an optional masking step, at least one adhesive can be applied to at least a portion of one or more surfaces of the earbud tip. The adhesive can be applied by spraying, roll coating, brush coating, dip coating, pad printing, or screen printing. The formed adhesive layer is configured to hold the flocking fibers in place.

[0031] In different embodiments, the adhesive can be a hot melt adhesive. In one or more embodiments, the adhesive can be water-based or organic solvent-based.

[0032] In one or more embodiments, the adhesive includes an acrylic-containing adhesive, a polyurethane-containing adhesive, a vinyl acetate-containing adhesive, or a combination of two or more of them. In certain embodiments, the adhesive includes a polyurethane adhesive, such as 851 from Parker Hannifan.

[0033] In one or more embodiments, the adhesive can include a crosslinking agent, such as an epoxy resin, etc.

[0034] Generally, the adhesive should be applied with as uniform a layer thickness as possible. In certain embodiments, it is desirable for the layer thickness of the dry adhesive to be about 1%-30%, 5%-15%, or about 10% of the average flocking fiber length. This ensures that the fibers are optimally anchored in the adhesive and can withstand stress.

[0035] Thus, the application of the adhesive results in the formation of an adhesive layer on one or more surfaces of the earbud tip. In one or more embodiments, the thickness of the adhesive layer (measured as a dry film) corresponds to at least 1%, 5%, or 10% and / or less than 50%, 45%, 40%, 35%, 30%, 25%, 20%, or 15% of the average flocking fiber length.

[0036] In one or more embodiments, the thickness of the adhesive layer (measured as a dry film) is at least 1 mil, 2 mils, 3 mils, 4 mils, or 5 mils and / or less than 25 mils, 20 mils, 15 mils, 10 mils, 9 mils, 8 mils, 7 mils, or 6 mils.

[0037] Generally, the time between the application of the adhesive and flocking should be as short as possible so that the adhesive does not dry before the fibers are bonded with sufficient density. The so-called "open time" of the adhesive depends on the adhesive and is specified in the manufacturer's handling instructions.

[0038] Subsequently, during the open time of the adhesive, the flocking step can occur. During the flocking step, multiple flocking fibers can be flocked onto at least a portion of the adhesive-covered surface. Generally, the flocking technique can be electrostatic flocking or electrostatic pneumatic flocking. In one or more embodiments, flocking is performed via a manual applicator, a flocking chamber unit, an electrostatic pneumatic flocking machine, or a flocking chamber with an extraction unit.

[0039] In one or more embodiments, the flocking technique is electrostatic flocking. Electrostatic flocking is a textile technique that uses Coulomb driving force to emit short fibers from a power supply to the adhesive-covered surface, thereby producing a dense array of fibers aligned perpendicular to the surface. More specifically, electrostatic flocking uses electric charges to direct the fibers and promote their vertical alignment. In this method, the adhesive-coated surface passes through a high-voltage electrostatic field, and the flocking fibers are charged using an electrode. The charged fibers become aligned with the electric field lines and are attracted to the grounded electrode. The flocking moves towards the adhesive-coated surface and becomes embedded. The fibers are bonded perpendicular to the surface, resulting in a dense pile finish. The electrostatic flocking method can be enhanced by pneumatic techniques for good coverage on three-dimensional objects.

[0040] In one or more embodiments, electrostatic flocking can be performed using a handheld electrostatic flocker with a blower to evenly coat the flocking fibers on the earplug tip. The handheld unit generally includes a metal plate, a generator, and a flocking head. The metal plate must be grounded. The generator generates electrostatic charges and can be wired to a can containing loose flocking fibers. A metal mesh can be installed midway inside the can opening. Then, the open end of the can is passed over the adhesive-coated surface, and the flocking fibers are suctioned through the mesh from the can. The electrostatic charges push the fibers towards the grounded metal plate. The adhesive-coated surface intercepts the fibers and flocking occurs. As further discussed below, the flocked surface can then be cured, and the loose fibers can be removed.

[0041] In addition, electrostatic flocking enables a high density of flocking fibers to be obtained on the treated surface because the fibers can stand upright due to the electro-orientation of the fibers. During the electrostatic flocking process, the flocking density or the number of fibers in a given area can be controlled by several factors. Without wishing to be bound by theory, the flocking fiber density can increase positively with the amount of time the electric field is present and with the mass of the fibers loaded onto the charged surface. Therefore, the flocking density can be controlled by adjusting the electric field strength and / or by changing the mass of the loaded flocking fibers.

[0042] The fiber density can be calculated based on the following formula: FD = n f / A f where "FD" is the fiber density, "n f " is the number of fibers in the field of view, and "A f” is the surface area of the visual field. The flocking fiber density can be measured using simple microscopic imaging and counting. In one or more embodiments, the flocked surface of the flocked earplug tip has a flocking fiber density of at least 5 fibers / mm 2 , 10 fibers / mm 2 , 15 fibers / mm 2 , 20 fibers / mm 2 , 25 fibers / mm 2 , 30 fibers / mm 2 , 35 fibers / mm 2 , 40 fibers / mm 2 , 45 fibers / mm 2 , 50 fibers / mm 2 , 55 fibers / mm 2 , 60 fibers / mm 2 , 65 fibers / mm 2 , 70 fibers / mm 2 , 75 fibers / mm 2 , 80 fibers / mm 2 , 85 fibers / mm 2 , 90 fibers / mm 2 , 95 fibers / mm 2 , 100 fibers / mm 2 , 105 fibers / mm 2 , 110 fibers / mm 2 , 115 fibers / mm 2 , 120 fibers / mm 2 , 125 fibers / mm 2 , 130 fibers / mm 2 , 135 fibers / mm 2 , 140 fibers / mm 2 , 145 fibers / mm 2 or 150 fibers / mm 2 , and / or less than 500 fibers / mm 2 , 450 fibers / mm 2 , 400 fibers / mm 2 , 350 fibers / mm 2 , 300 fibers / mm 2 , 250 fibers / mm 2 , 200 fibers / mm 2 , 175 fibers / mm 2 or 160 fibers / mm 2 .

[0043] In one or more embodiments, at least 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95% or 99% of the outer surface of the earbud tip has a flocked fiber density of at least 5 fibers / mm 2 , 10 fibers / mm 2 , 15 fibers / mm 2 , 20 fibers / mm 2 , 25 fibers / mm 2 , 30 fibers / mm 2 , 35 fibers / mm 2 , 40 fibers / mm 2 , 45 fibers / mm 2 , 50 fibers / mm 2 , 55 fibers / mm 2 , 60 fibers / mm 2 , 65 fibers / mm 2 , 70 fibers / mm 2 , 75 fibers / mm 2 , 80 fibers / mm 2 , 85 fibers / mm 2 , 90 fibers / mm 2 , 95 fibers / mm 2 , 100 fibers / mm 2 , 105 fibers / mm 2 , 110 fibers / mm 2 , 115 fibers / mm 2 , 120 fibers / mm 2 , 125 fibers / mm 2 , 130 fibers / mm 2 , 135 fibers / mm 2 , 140 fibers / mm 2 , 145 fibers / mm 2 or 150 fibers / mm 2 , and / or less than 500 fibers / mm 2 , 450 fibers / mm 2 , 400 fibers / mm 2 , 350 fibers / mm 2 , 300 fibers / mm 2 , 250 fibers / mm 2 , 200 fibers / mm 2 , 175 fibers / mm 2 or 160 fibers / mm 2 .

[0044] It may also be important to maintain a controlled atmosphere for flocking. Generally, the flocking area should have a relative humidity of about 60% and a temperature of 20°C to 25°C. Small changes in temperature or changes in the relative humidity percentage can result in a 3 to 4-fold change in the conductivity or electrical sensitivity of the flocked fibers and the substrate. If not properly maintained, these changes can have an adverse effect on the flocking process and may result in flocked balling, reduced adhesion, and flocking density.

[0045] The flocked fibers can be formed from any material capable of being flocked. In one or more embodiments, the flocked fibers are formed from polyamide (nylon 6 / 6, nylon 6 / 66, etc.), polyester (e.g., PET), acrylic, regenerated cellulose (e.g., rayon), cotton, polyolefin (e.g., PP), silk, or a combination of two or more thereof.

[0046] In one or more embodiments, the flocked fibers have an average length of at least 0.05 mm, 0.1 mm, 0.15 mm, 0.2 mm, 0.25 mm, 0.3 mm, or 0.35 mm, and / or less than 3.0 mm, 2.5 mm, 2.0 mm, 1.5 mm, 1.0 mm, 0.9 mm, 0.8 mm, 0.7 mm, 0.6 mm, 0.5 mm, or 0.4 mm. Additionally or in alternative embodiments, the average denier of the flocked fibers can be at least 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, or 0.8 and / or less than 2.0, 1.9, 1.8, 1.7, 1.6, 1.5, 1.4, 1.3, 1.2, 1.1, 1.0, or 0.9. Additionally or in alternative scenarios, in other embodiments, the flocked fibers can have an average diameter of at least 1 micron, 2 microns, 3 microns, 4 microns, 5 microns, 6 microns, 7 microns, 8 microns, 9 microns, 10 microns, 11 microns, 12 microns, 13 microns, 14 microns, 15 microns, 16 microns, 17 microns, 18 microns, 19 microns, or 20 microns, and / or less than 100 microns, 75 microns, 50 microns, 45 microns, 40 microns, 35 microns, 30 microns, 25 microns, 20 microns, 19 microns, 18 microns, 17 microns, 16 microns, or 15 microns.

[0047] The flocked fibers can have any cross-sectional shape, such as circular, leaf-shaped, square, or ribbon-shaped, etc. In certain embodiments, the flocked fibers have a circular cross-sectional shape.

[0048] Following the flocking step, at least a portion of the flocked earplug tip can be cured to effectively cure the adhesive and adhere the flocked fibers thereto. In one or more embodiments, curing includes heating at least a portion of the flocked earplug tip for a predetermined amount of time. The heating can be carried out in an oven or dryer (e.g., a continuous flow dryer or oven). Generally, the heating and drying conditions are specific to the adhesive used.

[0049] In one or more embodiments, curing is carried out at a temperature of at least 20°C, 25°C, 30°C, 35°C, 40°C, 45°C, 50°C, 55°C, 60°C, 65°C, 70°C, 75°C, 80°C, 85°C, 95°C, 100°C, 105°C, 110°C, 115°C, 120°C, 125°C, 130°C, 135°C, 140°C or 145°C. Additionally or alternatively, curing can be carried out at a temperature less than 300°C, 250°C, 200°C, 190°C, 180°C, 170°C, 160°C, 150°C, 140°C, 130°C, 120°C, 110°C, 100°C, 90°C, 80°C, 70°C, 60°C, 50°C or 40°C. Additionally or alternatively, in different embodiments, curing can occur over a period of at least 1 minute, 2 minutes, 3 minutes, 4 minutes, 5 minutes, 6 minutes, 7 minutes, 8 minutes, 9 minutes or 10 minutes and / or less than 60 minutes, 50 minutes, 40 minutes, 30 minutes, 20 minutes or 15 minutes.

[0050] After the curing step, at least a portion of the excess and loose flocked fibers can be removed from the flocked earplug tip. These removal techniques can include, for example, suction, tapping, brushing and / or washing. In one or more embodiments, the removal technique can involve jetting the flocked earplug tip with compressed gas (such as compressed air) to remove the loose fibers therefrom.

[0051] Optionally, after curing and / or removing the excess fibers, the flocked earplug tip can be coated with a protective coating. For example, at least a portion of the flocked earplug tip can be coated with an oleophobic and / or hydrophobic coating. The coating can be applied by dip coating, spray coating and / or brush coating. In certain embodiments, the coating includes fluorosilicone.

[0052] Due to the flocking process described herein, the outer surface of the flocked earbud tip (configured to contact the user's ear canal) can be substantially flocked. In one or more embodiments, based on the total surface area of the outer surface, at least 10%, 15%, 20%, 25%, 30%, 35, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95% or 99% of the outer surface of the earbud tip is covered with flocking fibers. Additionally or alternatively, based on the total surface area of the outer surface, less than 99%, 95%, 90%, 85%, 80%, 75% or 70% of the outer surface of the earbud tip can be covered with flocking fibers.

[0053] In one or more embodiments, based on the total surface area of the inner surface, at least 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95% or 99% of the inner surface of the earbud tip is covered with flocking fibers. Additionally or alternatively, based on the total surface area of the inner surface, less than 99%, 95%, 90%, 85%, 80%, 75% or 70% of the inner surface of the earbud tip can be covered with flocking fibers.

[0054] Due to the use of spacers and / or masking applications as discussed above, the internal space of the flocked earbud tip can have a very small flocked surface. In one or more embodiments, based on the total surface area of the inner surface, less than 99%, 90%, 80%, 70%, 60%, 50%, 40%, 30%, 20%, 10% or 5% of the inner surface of the earbud tip is covered with flocking fibers.

[0055] In Figures 1 - 8 exemplary embodiments of flocked earbud tips are provided.

[0056] Figures 1 - 4 Exemplary flocked earbud tips are depicted that can be used as AirPods replacement earbud tips for the first and second generations. As Figure 1 shown, the flocked earbud tip 10 can include a body having a flocked outer surface 12 and an inner tube 14 leading to a mesh barrier 16. The outer surface 12 of the body is generally the part of the flocked earbud tip that will contact the user's ear canal. Although not depicted as flocked in Figure 1 the inner tube 14 can be flocked with flocking fibers using the flocking methods described herein. As Figure 2 shown, the flocked earbud tip 10 can include a base 18 that can be configured to attach to a desired in-ear headphone. Figure 3A top view of a flocked earplug tip is provided and it is illustrated how preferably the mesh barrier 16 is kept unflocked to avoid blocking the mesh sieve barrier 16. As discussed above, during the flocking process, spacers and / or masking applications can be applied to the mesh barrier 16 to prevent flocking of the membrane. Figure 4 A bottom view of the flocked earplug tip 10 is provided and it is illustrated how the outer surface 12 can be flocked while the inner surface 20 of the body can be unflocked to reduce costs.

[0057] In one or more embodiments, based on the total surface area of the surface, at least 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95% or 99% of the surface (outer surface and / or inner surface) of the inner tube is covered with flocking fibers. Additionally or alternatively, based on the total surface area of the surface, less than 99%, 95%, 90%, 85%, 80%, 75% or 70% of the surface (outer surface and / or inner surface) of the inner tube can be covered with flocking fibers.

[0058] Figure 5 and Figure 6 Exemplary flocked earplug tip covers 100 according to different embodiments of the present disclosure are depicted, which can be used as covers for Generation 1 and Generation 2. As Figure 5 and Figure 6 shown, the flocked earplug tip cover 100 can include a flocked outer surface 102 of the body, which is configured to contact the user's ear canal. Additionally, the flocked earplug tip cover 100 can include apertures 104, 106, which are designed to facilitate the sound channels of the in-ear headphones. As Figure 6 shown, the inner surface 108 of the body of the flocked earplug tip cover 100 can be unflocked.

[0059] Figure 7 and Figure 8 Exemplary flocked earplug tip covers 200 according to different embodiments of the present disclosure are depicted, which can be used as covers for Generation 3. As Figure 7 and Figure 8 shown, the flocked earplug tip cover 200 can include a flocked outer surface 202 of the body, which is configured to contact the user's ear canal. Additionally, the flocked earplug tip cover 200 can include apertures 204, 206, 210, which are designed to facilitate the sound channels of the in-ear headphones. As Figure 8 shown, the inner surface 208 of the body of the flocked earplug tip cover 200 can be unflocked.

[0060] AlthoughFigures 1 - 8 Illustrates a specific embodiment of the flocked earplug tip of the present disclosure, but those skilled in the art will readily understand that the flocked earplug tip can be configured to be used with various audio and digital devices, including a variety of different in-ear headphones.

[0061] Compared to currently available conventional earplug tips, the flocked earplug tips disclosed herein can exhibit many improvements. For example, due to the presence of flocked fibers on the outer surface of the earplug tip, the grip of the earplug tip within the ear canal can be increased. While not wishing to be bound by theory, it is believed that the flocked fibers increase the surface area of the earplug tip, thereby increasing the frictional interaction between the earplug tip and the ear canal, which increases the grip of the earplug tip. This increased grip is even more significant when the earplug tip is wet (such as caused by sweating, etc.). In contrast, conventional silicone and foam earplug tips typically exhibit poor water and sweat resistance. When conventional foam and silicone earplug tips are wet (such as from sweat, etc.), they promote the formation of a smooth layer between the earplug tip and the ear canal, which results in the earplug tip detaching from the ear canal. In contrast, due to the presence of short flocked fibers, the flocked earplug tips of the present invention are capable of reducing the formation of such a smooth layer. Thus, the flocked earplug tips of the present disclosure are capable of better maintaining and holding an audio device (e.g., in-ear headphones) within the user's ear canal.

[0062] In addition, compared to conventional earplug tips (such as those made of foam, etc.), the flocked earplug tips of the present disclosure can exhibit excellent durability. Foam earplug tips typically lose their ability to expand within the ear canal due to continuous compression and decompression during use. In contrast, the flocked fibers do not exhibit these same defects after repeated use. Generally, the durability of the flocked earplug tip can be related to the adhesive used to form the flocked fiber layer. As long as the adhesive layer is maintained, the flocked earplug tip can be used without any impact on its performance.

[0063] Additionally, due to the flocked fiber layer, the earplug tips of the present disclosure can be more hygienic than conventional earplug tips. While not wishing to be bound by theory, it is believed that the flocked fibers provide a surface that is easier to clean, especially relative to foam earplug tips. For foam earplug tips, bacteria can be deep within the foam, thereby making such tips very difficult to clean. In contrast, the flocked fibers of the earplug tips of the present invention are easier to clean and are not conducive to the reproduction and growth of bacteria. Ideally, in various embodiments, the flocked fibers are applied to the surface area of the earplug tip that can come into contact with the user's earwax. Due to the characteristics of the flocked surface, it is easier to clean and remove earwax from the flocked surface.

[0064] Another benefit of the flocked earbud tips of the present disclosure is that they can provide excellent audio quality, especially when compared to foam earbud tips. Unlike foam, which tends to absorb sound, the flocked earbud tips can facilitate sound transmission into the user's ear canal by maintaining a good grip within the ear canal.

[0065] Definitions

[0066] It should be understood that the following is not intended to be an exclusive list of defined terms. Other definitions may be provided in the foregoing description, such as when used in conjunction with the use of terms defined in context.

[0067] As used herein, the terms "a", "an", and "the" mean one or more.

[0068] As used herein, the term "and / or", when used in a list of two or more items, means that any one of the listed items can be used alone or any combination of two or more of the listed items can be used. For example, if a composition is described as containing components A, B, and / or C, the composition can contain A alone; B alone; C alone; a combination of A and B; a combination of A and C; a combination of B and C; or a combination of A, B, and C.

[0069] As used herein, the terms "comprising", "comprises", and "comprise" are open transitional terms used to transition from the subject recited before the term to one or more elements recited after the term, where the one or more elements listed after the transitional term are not necessarily the only elements that make up the subject.

[0070] As used herein, the terms "having", "has", and "have" have the same open-ended meaning as "comprising", "comprises", and "comprise" provided above.

[0071] As used herein, the terms "including", "include", and "included" have the same open-ended meaning as "comprising", "comprises", and "comprise" provided above.

[0072] Numerical ranges

[0073] This specification uses numerical ranges to quantify certain parameters related to the present invention. It should be understood that when a numerical range is provided, such a range should be interpreted as providing literal support for claims that limit only to the lower value of the recited range and claims that limit only to the higher value of the recited range. For example, the disclosed numerical range of 10 to 100 provides literal support for claims reciting "greater than 10" (with no upper limit) and claims reciting "less than 100" (with no lower limit).

[0074] The claims are not limited to the disclosed embodiments

[0075] The preferred forms of the present invention described above are for illustrative purposes only and should not be used in a limiting sense to interpret the scope of the present invention. Those skilled in the art can readily modify the above exemplary embodiments without departing from the spirit of the present invention.

[0076] The inventors hereby state their intention to rely on the doctrine of equivalents to determine and evaluate the reasonable and fair scope of the present invention as it relates to any device that does not materially depart from the literal scope of the present invention as set forth in the following claims but is outside thereof.

Claims

1. A flocked earbud tip for an in-ear headphone, comprising a body having an outer surface and an inner surface, wherein, the flocked earbud tip is configured to fit into a user's ear canal, and wherein the outer surface is at least partially coated with a plurality of flocked fibers.

2. The flocked earbud tip according to claim 1, wherein, the flocked earbud tip is configured to replace an existing earbud tip on an in-ear headphone.

3. The flocked earbud tip according to claim 1, wherein, the flocked earbud tip is configured to cover an existing earbud tip on an in-ear headphone.

4. The flocked earbud tip according to any one of claims 1-3, wherein, the flocked fibers have an average length of less than 1.0 mm.

5. The flocked earbud tip according to any one of claims 1-4, wherein, the flocked fibers have an average denier of less than 1.

6.

6. The flocked earbud tip according to any one of claims 1-5, wherein, the body is formed of a material exhibiting a Shore A hardness of less than 50.

7. The flocked earbud tip according to any one of claims 1-6, wherein, an adhesive layer covers at least a portion of the outer surface, wherein the adhesive layer has a thickness corresponding to at least 1% and less than 50% of the average length of the flocked fibers.

8. A flocked earbud tip for an in-ear headphone, the flocked earbud tip comprising a body having an outer surface and an inner surface, wherein, the flocked earbud tip is configured to fit into a user's ear canal, wherein the outer surface is at least partially coated with a plurality of flocked fibers, wherein the flocked fibers have an average length of less than 0.7 mm and are formed of polyamide, polyester, regenerated cellulose, cotton, or a combination of two or more of polyamide, polyester, regenerated cellulose, and cotton, and wherein the body is formed of a material exhibiting a Shore A hardness of less than 50.

9. The flocked earbud tip according to claim 8, wherein, the flocked earbud tip is configured to replace an existing earbud tip on an in-ear headphone.

10. The flocked earbud tip according to claim 8, wherein, the flocked earbud tip is configured to cover an existing earbud tip on an in-ear headphone.

11. The flocked earbud tip according to any one of claims 8-10, wherein, the flocked fibers have an average length of less than 0.5 mm.

12. The flocked earbud tip according to any one of claims 8-11, wherein, the flocked fibers have an average denier of less than 1.

2.

13. The flocked earbud tip according to any one of claims 8-12, wherein, an adhesive layer covers at least a portion of the outer surface, wherein the adhesive layer has a thickness corresponding to at least 1% and less than 50% of the average length of the flocked fibers.

14. A method for forming a flocked earbud tip for an in-ear headphone, the method comprising: (a) providing an earbud tip configured to fit into a user's ear canal; (b) applying an adhesive to at least a portion of the surface of the earbud tip to form an adhesive-coated earbud tip; and (c) implanting a plurality of fibers onto at least a portion of the adhesive-coated earplug tip to form the flocked earplug tip.

15. The method according to claim 14, wherein, the flocking includes electrostatic flocking.

16. The method according to claim 14 or 15, further comprising curing the flocked earplug tip after the flocking in step (c) to cure the adhesive.

17. The method according to claim 16, further comprising applying a coating to at least a portion of the flocked earplug tip after curing.

18. The method according to any one of claims 14 to 17, further comprising pre-treating at least a portion of the earplug tip before step (b).

19. The method according to any one of claims 14 to 18, wherein, the fibers have an average length of less than 0.5 mm and an average denier of less than 1.

2.

20. The method according to any one of claims 14 to 19, wherein, the fibers are formed of polyamide, polyester, regenerated cellulose, cotton, or a combination of two or more of polyamide, polyester, regenerated cellulose, and cotton.

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