Double-flanged eartip and manufacturing method related thereof

Abstract

An eartip (1) comprising: - a stem (300) extending along an axial direction (2); - a second flange (201) extending radially and longitudinally from the stem (300), the second flange (201) comprising a second end (21) extending around and coupled to the stem (300) at a second axial coupling position (212) along the axial direction (2); and - a first flange (101) extending radially and longitudinally from the stem (300), the first flange (101) comprising a first end (11) extending around and coupled to the stem (300) at a first axial coupling position (111) along the axial direction (2); wherein the first flange (101) encompasses the second flange (201); wherein the first flange (101) and the second flange (201) contact each other along at least one contact line (40) encircling the stem (300) at a contact position (401) along the axial direction (2).

Description

Technical Field

[0001] The present invention generally relates to ear inserts and method of manufacturing thereof. More particularly, the present invention relates to an improved eartip for an ear insert such as an earplug.Background

[0002] An eartip provides an important interface between a human ear canal and an earplug, or an earbud, or an hearing aid, or any other suitable ear insert. It is commonly known that eartips, independently from the device to which they are connected, should provide substantial auditory isolation. This auditory isolation is necessary, for example, for blocking potentially damaging sounds from entering the user's ear canal. When used in combination with sound producing devices, auditory isolation is essential for isolating outside background noise that would interfere with the user's ability to clearly hear the sounds produced by the devices.

[0003] Most commonly found eartips are typically made of a foam or an elastomer material. The particular characteristics of the material used, such as for example durometer or density, have a significant impact on the ability of the eartip to conform to the individual ear canal, on the comfort reported by the user of the eartip, and particularly on the isolation from external sound. However, the geometry of the eartip can have an even greater impact on its ability not only to conform to the ear canal and its comfort for the user, but also on how effectively the eartip can isolate the ear canal from external sound.

[0004] Foam eartips usually provide the simplest geometry, often being conical or cylindrical pieces of foam. This type of eartip requires compression of the foam material prior to insertion in the ear canal, making the eartips susceptible to contamination and requiring replacement after every use. Domed and ribbed eartips are the most commonly used types of reusable eartips, and rely on the formation of multiple chambers or cavities along the longitudinal length of the eartip in order to create at least one airgap for sound attenuation. However, due to variations in the geometry and size of ear canals, domed and ribbed eartips tend to fit poorly to the ear of the user, usually developing ripples in the dome and / or ribs, and thus compromising the airtightness of the air chambers / cavities on which they rely for sound attenuation.Summary

[0005] It is an object of embodiments of the present disclosure to provide an eartip which provides improved sound attenuation by maintaining the airtightness of its at least one chamber / cavity and preserve the air gap contained therein. It is a particular object of the present disclosure to provide an eartip which provides superior sound attenuation by maintaining an airtight chamber / cavity while maintaining an airtight seal against the ear canal of the user.

[0006] Further to superior sound attenuation, the eartip according to the present disclosure advantageously balances internal pressure with compliance of the outer surface of the eartip, and thus provides also a continuous contact band which gently conforms to a wide range of ear canal geometries and dimensions.

[0007] The scope of protection sought for various embodiments of the invention is set out by the independent claims.

[0008] The embodiments and features described in this specification that do not fall within the scope of the independent claims, if any, are to be interpreted as examples useful for understanding various embodiments of the invention.

[0009] This object is achieved, according to a first example aspect of the present disclosure, by an eartip comprising: a stem extending along an axial direction; a second flange extending radially and longitudinally from the stem, wherein the second flange comprises a second end extending around and coupled to the stem at a second axial coupling position along the axial direction; and a first flange extending radially and longitudinally from the stem, wherein the first flange comprises a first end extending around and coupled to the stem at a first axial coupling position along the axial direction; wherein the first flange encompasses the second flange; wherein the first flange and the second flange contact each other along at least one contact line encircling the stem at a contact position along the axial direction; and wherein the second axial coupling position is comprised between the first axial coupling position and the contact position.

[0010] The first flange and the second flange advantageously form an air chamber between the stem of the eartip and the contact line between the two flanges. This contact line, continuous along a circumference, allows the chamber to be airtight, and in this way maintains a volume of air between the first flange and the second flange. This volume of air results in a substantial improvement in the sound attenuation. In order to preserve the airtightness of the chamber, the first flange is allowed to slide over the second flange. This allows the first flange to comply to a broader range of ear canal sizes and geometries without breaking the perimeter of the contact line with the second flange. In other words, even when inserted in an ear canal, the flanges of the eartip according to the present disclosure do not develop ripples in the dome and / or ribs, and thereby do not compromise the airtightness of the air chambers / cavities and thereby do not jeopardize the performance of the eartip for sound attenuation. Another advantage of allowing the first flange to slide over the second flange without breaking contact is that the second flange is allowed to move more freely when exposed to outside variation in air pressure, further improving sound attenuation. The first flange, being the outermost, and thus the most exposed flange of the two, advantageously provides an ideal balance between compliance and resistance to damage. To this end, the thickness of the first flange is preferably for example between 0.5mm and 0.65mm. This thickness of the first flange makes the eartips suitable to be used in a great variety of devices, from earplugs to sound producing devices used in a wide variety of environmental conditions, and without compromising comfort, hearing safety, and where applicable, sound quality.

[0011] Yet another advantage of allowing the first flange to slide over the second flange is to allow the first flange to more easily deform under pressure when the eartip is inserted into an ear canal. Because the first flange is able to deform under the air pressure created inside the ear canal while inserting the eartip into said ear canal, excess air is allowed to circumvent the outer surface of the eartip and leave the ear canal instead of impinging on the ear drum of the user. In this way, pressure buildup inside the ear canal, which would otherwise cause discomfort and even pain to the user, may be advantageously avoided.

[0012] In the context of the present disclosure, the terms cavity and chamber are to be understood to be equivalent, and to define the physical limits of a volume. In this context the term flange is to be understood as a large radial projection encircling the stem of the eartip. In this context, the term stem is to be understood as a long, thin supportive or main section of the eartip. In this context, the term encircling is to be understood as equivalent to forming a circle, to surround an element e.g. each flange of the eartip encircles the stem. In the context of the present concept, the term comprised between is used to define a range by means of at least two boundary elements and / or numerical values, which range may be unidimensional (e.g. distance, pH) or multidimensional (e.g. area, volume). In this context, the term position or positions are used to refer to positions determined by projection along the axial direction of the stem.

[0013] According to example embodiments: the stem may comprise a proximal end and an opposite distal end; the first flange may further comprise a first rim formed at a first rim position along the axial direction and being radially inwardly deflected; the second flange may further comprise a second rim formed at a second rim position along the axial direction; and wherein the second rim position may be closer to the proximal end along the axial direction than the first rim position.

[0014] Preferably, the inward deflection may be 0.5mm, 0.6mm, 0.7mm, 0.8mm, 0.9mm, 1 mm, most preferably 1.2mm at the first rim. By preference the second rim position and the first rim position may be distanced 1mm from each other along the axial direction, more preferably 1.5mm, 2mm, 2.5mm, most preferably 3mm. This way, the contact line is able to shift along the axial direction as the outer perimeter of the first flange is constrained or relaxed. This permits maintaining the contact line even when the eartip is inserted in ear canals of widely different sizes, thus maintaining an airtight seal against the walls of the ear canal for a very wide range of ear canal dimensions. In this way, the airtight chamber between the first flange and the second flange is guaranteed to be preserved, and with it the damping of any external vibrations, and the attenuation of external sounds.

[0015] According to example embodiments, a thickness of the first flange at the first end may be 5% to 45% larger than a thickness of the first flange at the first rim.

[0016] Preferably, the thickness of the first flange at the first end may be 10% to 40%, more preferably 15% to 30%, most preferably 20% to 25% larger than the thickness of the first flange at the first rim. In this way, the first flange may become more flexible towards the first rim position, while maintaining a stiffer portion near the first axial coupling position. This advantageously permits maintaining a rigid central portion of the eartip, allowing for easier insertion of the eartip in the ear canal, while having the first flange with a pliable section where its outer surface is susceptible to contact the ear canal, and thereby providing an area on the first flange that better conforms to the ear canal.

[0017] According to example embodiments, the stem may extend less along the axial direction than the first flange and the second flange.

[0018] This way, sound propagating in the stem of the eartip is attenuated for a user of the eartip along the entire length of the stem of the eartip along the axial direction. This permits the creation of at least one additional air chamber when a an outer ear device is coupled to the eartip, and in this way further increasing sound attenuation. Another advantage is that insertion of the eartip too far into the ear canal is avoided, thereby preventing damage to the ear drum. Yet another advantageous effect is having the stem, and more in particular, the distal end of the stem of the eartip encompassed by the first flange and the second flange is that the portion where the stem may couple with other elements, such as an outer ear structure, is advantageously covered by the flanges. In this way, the ear canal in not exposed to sharp edges which might cause scratching and / or scraping of the ear canal, and potentially cause ear infections. By preference the distal end of the stem may extend 1mm less along the axial direction than the first flange and the second flange, more preferably 2mm, 2.5mm, 3mm, 3.5mm, most preferably the distal end of the stem extends 5mm less along the axial direction than the first flange. This permits accommodating a wide range of outer ear devices and still protect the ear canal of the user from any sharp edges.

[0019] According to example embodiments, the opposite distal end may be adapted to be coupled to an outer ear structure.

[0020] This makes the eartip advantageously versatile and compatible with a vast plurality of devices. Such an outer ear structure may be for example a head-phone, ear-bud, hearing aid, ear-plug or other external sound producing / control element. Preferably, the distal portion of the stem may be adapted to be coupled to an outer ear structure by means of a connector near the distal end of the stem and / or an opening on the distal end of the stem. More preferably, the connector may be a thread or hooking collar, the hooking collar having at least one bevelled distal edge and an abutment surface directed towards the proximal end of the eartip. Most preferably, the connector may be an internal hooking collar inside a cavity extending from an opening on the distal end of the stem. The hooking collar advantageously provides a more robust attachment between the outer ear structure and the eartip, allowing the user to pull on the outer ear structure to easily remove the eartip from the ear canal. The inner hooking collar guarantees also that the eartip may encapsulate all coupling features of the outer ear structure, thus providing a more streamlined and softer outer surface at and near the distal end of the stem. The cavity may extend along the whole length if the stem, from the proximal end to the opposite distal end. Such a cavity permits the use of the eartip in combination with sound emitting outer ear devices such as, but not limited to, hearing aids and ear buds. This full length cavity permits also the adjustment of sound damping properties based on the outer ear structure used in combination with the eartip. For example, an outer ear structure having a longitudinal channel of a specific diameter commensurate with a desired sound damping level may be used. The cavity may also be provided with one or more membranes between the proximal end to the opposite distal end, the membranes having a thickness between 0.05mm and 0.4mm. Such at least one membrane provides an advantageous barrier against contam inants.

[0021] According to example embodiments, the first flange and the second flange may contact each other along a contact surface, wherein the contact surface may enclose the stem.

[0022] This contact surface may advantageously increase the contact between the first flange and the second flange, resulting in a more effective airtight sealing of the cavity, and as a consequence, also improving the sound dampening provided by the eartip. This contact surface further permits reducing any pressure exerted by the first flange on the surface of the ear canal by distributing the same or similar force over a larger area. In this way, the eartip may have an improved seal between the outer surface of the first flange and the ear canal of the user, and without having any detrimental effect to the comfort of the eartip. By preference, said contact surface may be characterized by a diameter and a width, said width extending along the outer surface of the first flange and in an axial direction. More preferably said width may measure between 0.5mm and 5mm, 1mm and 4mm, 1.5mm and 3.5mm, most preferably between 2mm and 3mm, depending on the diameter of the ear canal of the user.

[0023] According to example embodiments, a diameter of the first flange at the first rim position may be smaller than a diameter of the second flange at the second rim position.

[0024] In this way, the second flange may more easily be kept encompassed by the first flange even when the first flange is pressed inwards e.g. by the ear canal during or after insertion of the eartip in said ear canal. This permits a better fit of the eartip to a wider range of ear canal dimension and, more importantly, without the contact line or area between the first flange and the second flange being broken. by preserving the integrity of contact line or area between the first flange and the second flange, the eartip maintains constant sound damping properties independently of the dimensions of the ear canal of the user.

[0025] According to example embodiments, the first flange and the second flange may comprise an elastomeric polymer.

[0026] This elastomeric polymer may be one or more polymers chosen from the group of thermoplastic elastomers (TPE), e.g. thermoplastic polyurethane (TPU), rubber like polymers like natural rubber, nitrile rubber, Ethylene-Propylene-Diene-Monomer (EPDM) rubbers, Acrylonitrile-butadiene-styrene (ABS), Polycarbonate / acrylonitrile butadiene styrene (PC-ABS), silicone rubbers (also referred to as silicone), Polyesters (PES), polyamide (PA, like PA6, PA6.6, PA6.10, and alike), Acrylic or Polymethyl Methacrylate (PMMA), Polycarbonate (PC), Polyethylene (PE), Polypropylene (PP), Polyethylene Terephthalate (PETE or PET), Polyvinyl Chloride (PVC), Polyoxymethylene (POM), and similar and combinations of two or more of these polymers. Silicone polymers are better tolerated by the end users having a more comfortable skin contact, and are therefore the preferred material for the eartip. The polymer may comprise additives such as organic or inorganic fillers. In order to modify the hardness of the silicone polymers, more or less silicone oils or gum, more or less or alternative fillers or more or less couplers or cross linking agents may be added, higher or lower molecular weight for the silicone polymers may be used, and / or the curing time of the polymer may be modified. Preferably, the first flange and the second flange of the eartip are flexible, and in this way promote uninterrupted contact between the first flange and the second flange at the contact line or area, better comfort and better conformity with the shape and size of the ear canal of the end user.

[0027] According to example embodiments, the first flange may further comprise a first inward wall of the first flange facing the second flange and wherein the second flange may further comprise a second outward wall of the second flange facing the first flange.

[0028] In this way, the first rim of the first flange and the second rim of the second flange are both open towards the distal end of the eartip, and thus, placing the contact line / area of the first flange and the second flange advantageously inside the wider section of the ear canal, when the eartip is inserted in that ear canal. This may further increase the contact area between the first flange and the ear canal, further reducing the pressure exerted by the former on the surface of the latter, greatly enhancing the comfort of the end user, while improving the sealing of the first flange against the ear canal of the user.

[0029] According to example embodiments, at least the first inward wall of the first flange facing the second flange and the second outward wall of the second flange facing the first flange may be provided with a friction-reducing coating, wherein the friction-reducing coating may comprise the following: antistatic UV surface treatment; and / or a layer of siloxane-based silicone coating.

[0030] Preferably, the second outward wall of the first flange may be provided with a friction-reducing coating. This coating advantageously eases the insertion and removal of the eartip into and from the ear canal. Given the sticky nature of freshly molded silicone, the friction-reducing coating advantageously may also eliminate the adhesion of debris or other contaminants to the eartip, providing greatly improved hygiene. More preferably, all the surfaces of the eartip are provided with a friction-reducing coating, most preferably said coating is a layer of siloxane-based silicone coating. This allows the first flange to slide effortlessly against the second flange, and in this way preventing any kinks or bending of any of the flanged at or near the contact line or area, which permits retaining airtightness at the contact line or area encompassing the air volume inside the at least one chamber. By preference, this coating may have a thickness between 0.05mm and 0.4mm, e.g. 0.05mm, 0.1mm, 0.15mm, 0.2mm, 0.25mm, 0.3mm, 0.35mm, 0.4mm. This siloxane based silicone coat may preferably comprise 30% of silica in its composition,. In this way, the friction reducing coating may demonstrate a non-sticky surface while still providing some grip, in particular when the surface of the friction reducing coating is in contact with the skin of the ear canal of the user, thus preventing the eartips from easily falling from the ears of the user. To further enhance the retention properties of the eartip, the friction reducing coating of the eartip may have an imprinted textured surface. To this end, a texture of VDI 21 was found to provide the ideal texture which may provide sufficient grip against the skin of the ear canal of the user while still feeling smooth and comfortable to the touch. However, textures between VDI 16 and VDI 26 may also be used if preferred by the user, e.g. if the eartip is to be used in warmer environments a coarser surface may be found to be necessary.

[0031] According to example embodiments, an angle between the first inward wall of the first flange and the second outward wall of the second flange may be comprised between 0° and 20.

[0032] This range of the an angle between the first inward wall of the first flange and the second outward wall of the second flange advantageously provide a balance between the pressure exerted by the second flange on the first inside wall of the first flange, and the size of the contact area between the contact area between the same. In this way, a cavity formed between the first inward wall of the first flange and the second outward wall of the second flange, as well as the contact area between said two flanges provide a more substantial sound damping performance. In order to provide adequate support under the first flange, the second flange may have a thickness comprised between 0.35mm and 0.45mm, by preference 0.4mm. Preferably, the angle between the first inward wall of the first flange and the second outward wall of the second flange is measured near the second rim, e.g. 1mm, 2mm or 3mm away from said second rim in a proximal direction, most preferably 1mm from the second rim in a proximal direction. This advantageously ensures that the angle between the first inward wall of the first flange and the second outward wall of the second flange may still fall within the desired range, even when the outer surface of the first flange is constrained by the ear canal of the user. By keeping this angle range for a wide range of ear canal dimensions, a continuous contact line or area is advantageously kept, which allows the maintenance of an immovable volume of air inside the chamber between the first flange and the second flange.

[0033] According to example embodiments, an angle between the first inward wall of the first flange and the stem may be comprised between 70° and 80°.

[0034] This angle between the first inward wall of the first flange and the stem provides an optimal balance between ease of insertion of the eartip in the ear canal, and wider range of ear canal dimensions to which the eartip can conform, while still being able to maintain the airtightness of the chamber between the first flange and the second flange.

[0035] According to example embodiments, the second flange may further comprise a second inward wall facing the stem; and wherein an angle between the second inward wall of the second flange and the stem may be comprised between 35° and 45°.

[0036] In this way, an optimal balance may be provided between the tension provided by the second flange against the first flange, and the volume of the a cavity formed between the first inward wall of the first flange and the second outward wall of the second flange. As a result, a more substantial sound damping performance may be obtained.

[0037] According to a second example aspect of the present disclosure, a method of manufacturing an eartip is provided, wherein the method comprises the steps of: forming an eartip structure comprising: ∘ a stem extending along an axial direction; ∘ a second flange extending radially and longitudinally from the stem, wherein the second flange comprises a second end extending around and coupled to the stem at a second axial coupling position along the axial direction; ∘ a first inverted flange extending radially and longitudinally from the stem, wherein the first inverted flange comprises a first end extending around and coupled to the stem at a first axial coupling position along the axial direction; and inverting the first inverted flange along the axial direction, thereby forming a first flange wherein: ∘ the first flange encompasses the second flange; ∘ the first flange and the second flange contact each other along at least one contact line encircling the stem at a contact position along the axial direction; and ∘ the second axial coupling position is comprised between the first axial coupling position and the contact position.

[0038] Hence, the method according to the second example aspect of the present disclosure may provide an ear plug according to the first example aspect of the present disclosure. The forming of the ear tip may preferably be performed by means of a mold, more preferably by injection molding. In this way, the eartips may more easily and economically be produced. By molding the first flange in an inverted position, the need for a complex mold is obviated, further reducing the initial cost of production while also making extraction of the formed eartips form the mold much easier and without the risk of tearing the delicate flanges of the eartip.

[0039] According to example embodiments, the method may further comprise the steps of: providing a mold for forming the eartip structure, wherein the mold may comprise an inner surface; coating at least the inner surface of the mold with a friction-reducing coating comprising the following: ∘ a layer of UV-curable layer of silicone rubber; and / or ∘ a layer of siloxane-based silicone coating; providing an elastomeric polymer in the mold, thereby forming the eartip structure.

[0040] For this purpose of providing a friction reducing coating, the mold being used may be a metal, ceramic and / or crystal mold. The mold used may have one shell, preferably more shells. The mold may have two shells wherein one of the shells is a transparent shell, possibly quartz, glass or ceramic. This mold with transparent shell is particularly suited for the application of a UV treatment to a layer of UV-curable silicone. In order to more fully apply a UV treatment to the surface of the eartip, all shells of the mold may be made of transparent quartz, glass or ceramic. Preferably, the second outward wall of the first flange may be provided with a fiction-reducing coat. More preferably, all the surfaces of the eartip are provided with a friction-reducing coating, most preferably said coating is a layer of siloxane-based silicone coating. By preference, this coating may have a thickness between 0.05mm and 0.4mm, e.g. 0.05mm, 0.1mm, 0.15mm, 0.2mm, 0.25mm, 0.3mm, 0.35mm, 0.4mm. A preferred embodiment of the method, in particular the step of coating at least the inner surface of the mold with a friction-reducing coating includes the application of a layer of siloxane-based silicone coating to the interior of the mold. This siloxane based silicone preferably comprises at least 20% silica, more preferably 22%, 24%, 26%, 28, most preferably 30% of silica in its composition. In this way, the friction reducing coating will retain a non-sticky surface while still provide some grip, in particular when the surface of said friction reducing coating is in contact with the skin of the ear canal of the user, thus preventing the eartips from easily falling from the ears of the user. To further enhance the retention properties of the eartip, the molds used are provided with a textured internal surface, which textured surface will imprint on the friction reducing coating. To this end, a texture of VDI 21 was found to provide the ideal texture which may provide sufficient grip against the skin of the ear canal of the user while still feeling smooth and comfortable to the touch. However, textures between VDI 16 and VDI 26 may also be used if preferred by the user, e.g. if the eartip is to be used in warmer environments a coarser surface may be found to be necessary.

[0041] It is understood that features from one of the aspects of the invention may be combined with one or more, even all features of one or more of the other aspects of the invention.

[0042] In general, when for a feature, reference is made to a range, the range is to be understood inclusive, unless explicitly mentioned differently.Brief Description of the Drawings

[0043] Fig. 1 schematically illustrates an example embodiment of an eartip according to the first aspect of the present disclosure; and Fig. 2 schematically illustrates an example embodiment of an eartip as obtained after the step of forming according to the second aspect of the present disclosure. Detailed Description of Embodiment(s)

[0044] Fig. 1 schematically illustrates an example embodiment of an eartip 1 according to the first aspect of the present disclosure. The eartip 1 is shown comprising a stem 300 extending along an axial direction 2, from which stem 300 a second flange 201 extends radially and longitudinally, wherein the second flange 201 comprises a second end 21 extending around and coupled to the stem 300 at a second axial coupling position 212 along the axial direction 2. The eartip 1 is shown further comprising a first flange 101 extending radially and longitudinally from the stem 300, wherein the first flange 101 comprises a first end 11 extending around and coupled to the stem 300 at a first axial coupling position 111 along the axial direction 2; wherein the first flange 101 encompasses the second flange 201. The first flange 101 and the second flange 201 are shown in contact each other along at least one contact line 40 encircling the stem 300 at a contact position 401 along the axial direction 2. This second axial coupling position 212 is comprised between the first axial coupling position 111 and the contact position 401. The first flange 101 further comprises a first rim 12 formed at a first rim position 121 along the axial direction 2 and being radially inwardly deflected. The second flange 201 further comprises a second rim 22 formed at a second rim position 221 along the axial direction 2. The second rim position 221 shown closer to the proximal end 31 along the axial direction 2 than the first rim position 121. The first flange 101 is shown with a visible taper wherein the thickness of the first flange 101 gradually reduces towards the first rim 12. The opposite distal end 32 is adapted to be coupled to an outer ear structure by means of second axial coupling position 212. In Fig. 1 the stem 300 is shown provided with a hollow channel along its entire length.

[0045] Fig. 2 schematically illustrates an example embodiment of an eartip 1 as obtained after the step of forming according to the second aspect of the present disclosure. The eartip 1 is shown comprising a stem 300 extending along an axial direction 2, from which stem 300 a second flange 201 extends radially and longitudinally, wherein the second flange 201 comprises a second end 21 extending around and coupled to the stem 300 at a second axial coupling position 212 along the axial direction 2. The eartip 1 is shown further comprising a first flange 101 a first inverted flange 501 extending radially and longitudinally from the stem 300, wherein the first inverted flange 501 comprises a first end 11 extending around and coupled to the stem 300 at a first axial coupling position 111 along the axial direction 2. This second axial coupling position 212 is comprised between the first axial coupling position 111 and the opposite distal end 32 of the stem.300 The first flange 101 further comprises a first rim 12 formed at a first rim position 121 along the axial direction 2 and being radially inwardly deflected. The first rim position 121 being shown proximally located relative to the first axial coupling position 111. The second flange 201 further comprises a second rim 22 formed at a second rim position 221 along the axial direction (2). The second rim position 221 shown closer to the proximal end 31 along the axial direction 2 than the first rim position 121. The first flange 101 is shown with a visible taper wherein the thickness of the first flange 101 gradually reduces towards the first rim 12. The opposite distal end 32 is adapted to be coupled to an outer ear structure by means of second axial coupling position 212. In Fig. 2 the stem 300 is shown provided with a hollow channel along its entire length. In the configuration shown in Fig. 2, the eartip 1 is ready for a step of inverting the first flange over the first axial coupling position 111 and towards the opposite distal end 32 of the stem 300 in order to rendered ready to be used as shown in Fig. 1.

[0046] Although the present concept has been illustrated by reference to specific embodiments, it will be apparent to those skilled in the art that the concept is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied with various changes and modifications without departing from the scope thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. In other words, it is contemplated to cover any and all modifications, variations or equivalents that fall within the scope of the basic underlying principles and whose essential attributes are claimed in this patent application. It will furthermore be understood by the reader of this patent application that the words "comprising" or "comprise" do not exclude other elements or steps, that the words "a" or "an" do not exclude a plurality, and that a single element, such as a computer system, a processor, or another integrated unit may fulfil the functions of several means recited in the claims. Any reference signs in the claims shall not be construed as limiting the respective claims concerned. The terms "first", "second", third", "a", "b", "c", and the like, when used in the description or in the claims are introduced to distinguish between similar elements or steps and are not necessarily describing a sequential or chronological order. Similarly, the terms "top", "bottom", "over", "under", and the like are introduced for descriptive purposes and not necessarily to denote relative positions. It is to be understood that the terms so used are interchangeable under appropriate circumstances and embodiments of the invention are capable of operating according to the present invention in other sequences, or in orientations different from the one(s) described or illustrated above.

Examples

Embodiment Construction

[0044]Fig. 1 schematically illustrates an example embodiment of an eartip 1 according to the first aspect of the present disclosure. The eartip 1 is shown comprising a stem 300 extending along an axial direction 2, from which stem 300 a second flange 201 extends radially and longitudinally, wherein the second flange 201 comprises a second end 21 extending around and coupled to the stem 300 at a second axial coupling position 212 along the axial direction 2. The eartip 1 is shown further comprising a first flange 101 extending radially and longitudinally from the stem 300, wherein the first flange 101 comprises a first end 11 extending around and coupled to the stem 300 at a first axial coupling position 111 along the axial direction 2; wherein the first flange 101 encompasses the second flange 201. The first flange 101 and the second flange 201 are shown in contact each other along at least one contact line 40 encircling the stem 300 at a contact position 401 along the axial directi...

Technical Field

[0001] The present invention generally relates to ear inserts and method of manufacturing thereof. More particularly, the present invention relates to an improved eartip for an ear insert such as an earplug.Background

[0002] An eartip provides an important interface between a human ear canal and an earplug, or an earbud, or an hearing aid, or any other suitable ear insert. It is commonly known that eartips, independently from the device to which they are connected, should provide substantial auditory isolation. This auditory isolation is necessary, for example, for blocking potentially damaging sounds from entering the user's ear canal. When used in combination with sound producing devices, auditory isolation is essential for isolating outside background noise that would interfere with the user's ability to clearly hear the sounds produced by the devices.

[0003] Most commonly found eartips are typically made of a foam or an elastomer material. The particular characteristics of the material used, such as for example durometer or density, have a significant impact on the ability of the eartip to conform to the individual ear canal, on the comfort reported by the user of the eartip, and particularly on the isolation from external sound. However, the geometry of the eartip can have an even greater impact on its ability not only to conform to the ear canal and its comfort for the user, but also on how effectively the eartip can isolate the ear canal from external sound.

[0004] Foam eartips usually provide the simplest geometry, often being conical or cylindrical pieces of foam. This type of eartip requires compression of the foam material prior to insertion in the ear canal, making the eartips susceptible to contamination and requiring replacement after every use. Domed and ribbed eartips are the most commonly used types of reusable eartips, and rely on the formation of multiple chambers or cavities along the longitudinal length of the eartip in order to create at least one airgap for sound attenuation. However, due to variations in the geometry and size of ear canals, domed and ribbed eartips tend to fit poorly to the ear of the user, usually developing ripples in the dome and / or ribs, and thus compromising the airtightness of the air chambers / cavities on which they rely for sound attenuation.Summary

[0005] It is an object of embodiments of the present disclosure to provide an eartip which provides improved sound attenuation by maintaining the airtightness of its at least one chamber / cavity and preserve the air gap contained therein. It is a particular object of the present disclosure to provide an eartip which provides superior sound attenuation by maintaining an airtight chamber / cavity while maintaining an airtight seal against the ear canal of the user.

[0006] Further to superior sound attenuation, the eartip according to the present disclosure advantageously balances internal pressure with compliance of the outer surface of the eartip, and thus provides also a continuous contact band which gently conforms to a wide range of ear canal geometries and dimensions.

[0007] The scope of protection sought for various embodiments of the invention is set out by the independent claims.

[0008] The embodiments and features described in this specification that do not fall within the scope of the independent claims, if any, are to be interpreted as examples useful for understanding various embodiments of the invention.

[0009] This object is achieved, according to a first example aspect of the present disclosure, by an eartip comprising: a stem extending along an axial direction; a second flange extending radially and longitudinally from the stem, wherein the second flange comprises a second end extending around and coupled to the stem at a second axial coupling position along the axial direction; and a first flange extending radially and longitudinally from the stem, wherein the first flange comprises a first end extending around and coupled to the stem at a first axial coupling position along the axial direction; wherein the first flange encompasses the second flange; wherein the first flange and the second flange contact each other along at least one contact line encircling the stem at a contact position along the axial direction; and wherein the second axial coupling position is comprised between the first axial coupling position and the contact position.

[0010] The first flange and the second flange advantageously form an air chamber between the stem of the eartip and the contact line between the two flanges. This contact line, continuous along a circumference, allows the chamber to be airtight, and in this way maintains a volume of air between the first flange and the second flange. This volume of air results in a substantial improvement in the sound attenuation. In order to preserve the airtightness of the chamber, the first flange is allowed to slide over the second flange. This allows the first flange to comply to a broader range of ear canal sizes and geometries without breaking the perimeter of the contact line with the second flange. In other words, even when inserted in an ear canal, the flanges of the eartip according to the present disclosure do not develop ripples in the dome and / or ribs, and thereby do not compromise the airtightness of the air chambers / cavities and thereby do not jeopardize the performance of the eartip for sound attenuation. Another advantage of allowing the first flange to slide over the second flange without breaking contact is that the second flange is allowed to move more freely when exposed to outside variation in air pressure, further improving sound attenuation. The first flange, being the outermost, and thus the most exposed flange of the two, advantageously provides an ideal balance between compliance and resistance to damage. To this end, the thickness of the first flange is preferably for example between 0.5mm and 0.65mm. This thickness of the first flange makes the eartips suitable to be used in a great variety of devices, from earplugs to sound producing devices used in a wide variety of environmental conditions, and without compromising comfort, hearing safety, and where applicable, sound quality.

[0011] Yet another advantage of allowing the first flange to slide over the second flange is to allow the first flange to more easily deform under pressure when the eartip is inserted into an ear canal. Because the first flange is able to deform under the air pressure created inside the ear canal while inserting the eartip into said ear canal, excess air is allowed to circumvent the outer surface of the eartip and leave the ear canal instead of impinging on the ear drum of the user. In this way, pressure buildup inside the ear canal, which would otherwise cause discomfort and even pain to the user, may be advantageously avoided.

[0012] In the context of the present disclosure, the terms cavity and chamber are to be understood to be equivalent, and to define the physical limits of a volume. In this context the term flange is to be understood as a large radial projection encircling the stem of the eartip. In this context, the term stem is to be understood as a long, thin supportive or main section of the eartip. In this context, the term encircling is to be understood as equivalent to forming a circle, to surround an element e.g. each flange of the eartip encircles the stem. In the context of the present concept, the term comprised between is used to define a range by means of at least two boundary elements and / or numerical values, which range may be unidimensional (e.g. distance, pH) or multidimensional (e.g. area, volume). In this context, the term position or positions are used to refer to positions determined by projection along the axial direction of the stem.

[0013] According to example embodiments: the stem may comprise a proximal end and an opposite distal end; the first flange may further comprise a first rim formed at a first rim position along the axial direction and being radially inwardly deflected; the second flange may further comprise a second rim formed at a second rim position along the axial direction; and wherein the second rim position may be closer to the proximal end along the axial direction than the first rim position.

[0014] Preferably, the inward deflection may be 0.5mm, 0.6mm, 0.7mm, 0.8mm, 0.9mm, 1 mm, most preferably 1.2mm at the first rim. By preference the second rim position and the first rim position may be distanced 1mm from each other along the axial direction, more preferably 1.5mm, 2mm, 2.5mm, most preferably 3mm. This way, the contact line is able to shift along the axial direction as the outer perimeter of the first flange is constrained or relaxed. This permits maintaining the contact line even when the eartip is inserted in ear canals of widely different sizes, thus maintaining an airtight seal against the walls of the ear canal for a very wide range of ear canal dimensions. In this way, the airtight chamber between the first flange and the second flange is guaranteed to be preserved, and with it the damping of any external vibrations, and the attenuation of external sounds.

[0015] According to example embodiments, a thickness of the first flange at the first end may be 5% to 45% larger than a thickness of the first flange at the first rim.

[0016] Preferably, the thickness of the first flange at the first end may be 10% to 40%, more preferably 15% to 30%, most preferably 20% to 25% larger than the thickness of the first flange at the first rim. In this way, the first flange may become more flexible towards the first rim position, while maintaining a stiffer portion near the first axial coupling position. This advantageously permits maintaining a rigid central portion of the eartip, allowing for easier insertion of the eartip in the ear canal, while having the first flange with a pliable section where its outer surface is susceptible to contact the ear canal, and thereby providing an area on the first flange that better conforms to the ear canal.

[0017] According to example embodiments, the stem may extend less along the axial direction than the first flange and the second flange.

[0018] This way, sound propagating in the stem of the eartip is attenuated for a user of the eartip along the entire length of the stem of the eartip along the axial direction. This permits the creation of at least one additional air chamber when a an outer ear device is coupled to the eartip, and in this way further increasing sound attenuation. Another advantage is that insertion of the eartip too far into the ear canal is avoided, thereby preventing damage to the ear drum. Yet another advantageous effect is having the stem, and more in particular, the distal end of the stem of the eartip encompassed by the first flange and the second flange is that the portion where the stem may couple with other elements, such as an outer ear structure, is advantageously covered by the flanges. In this way, the ear canal in not exposed to sharp edges which might cause scratching and / or scraping of the ear canal, and potentially cause ear infections. By preference the distal end of the stem may extend 1mm less along the axial direction than the first flange and the second flange, more preferably 2mm, 2.5mm, 3mm, 3.5mm, most preferably the distal end of the stem extends 5mm less along the axial direction than the first flange. This permits accommodating a wide range of outer ear devices and still protect the ear canal of the user from any sharp edges.

[0019] According to example embodiments, the opposite distal end may be adapted to be coupled to an outer ear structure.

[0020] This makes the eartip advantageously versatile and compatible with a vast plurality of devices. Such an outer ear structure may be for example a head-phone, ear-bud, hearing aid, ear-plug or other external sound producing / control element. Preferably, the distal portion of the stem may be adapted to be coupled to an outer ear structure by means of a connector near the distal end of the stem and / or an opening on the distal end of the stem. More preferably, the connector may be a thread or hooking collar, the hooking collar having at least one bevelled distal edge and an abutment surface directed towards the proximal end of the eartip. Most preferably, the connector may be an internal hooking collar inside a cavity extending from an opening on the distal end of the stem. The hooking collar advantageously provides a more robust attachment between the outer ear structure and the eartip, allowing the user to pull on the outer ear structure to easily remove the eartip from the ear canal. The inner hooking collar guarantees also that the eartip may encapsulate all coupling features of the outer ear structure, thus providing a more streamlined and softer outer surface at and near the distal end of the stem. The cavity may extend along the whole length if the stem, from the proximal end to the opposite distal end. Such a cavity permits the use of the eartip in combination with sound emitting outer ear devices such as, but not limited to, hearing aids and ear buds. This full length cavity permits also the adjustment of sound damping properties based on the outer ear structure used in combination with the eartip. For example, an outer ear structure having a longitudinal channel of a specific diameter commensurate with a desired sound damping level may be used. The cavity may also be provided with one or more membranes between the proximal end to the opposite distal end, the membranes having a thickness between 0.05mm and 0.4mm. Such at least one membrane provides an advantageous barrier against contam inants.

[0021] According to example embodiments, the first flange and the second flange may contact each other along a contact surface, wherein the contact surface may enclose the stem.

[0022] This contact surface may advantageously increase the contact between the first flange and the second flange, resulting in a more effective airtight sealing of the cavity, and as a consequence, also improving the sound dampening provided by the eartip. This contact surface further permits reducing any pressure exerted by the first flange on the surface of the ear canal by distributing the same or similar force over a larger area. In this way, the eartip may have an improved seal between the outer surface of the first flange and the ear canal of the user, and without having any detrimental effect to the comfort of the eartip. By preference, said contact surface may be characterized by a diameter and a width, said width extending along the outer surface of the first flange and in an axial direction. More preferably said width may measure between 0.5mm and 5mm, 1mm and 4mm, 1.5mm and 3.5mm, most preferably between 2mm and 3mm, depending on the diameter of the ear canal of the user.

[0023] According to example embodiments, a diameter of the first flange at the first rim position may be smaller than a diameter of the second flange at the second rim position.

[0024] In this way, the second flange may more easily be kept encompassed by the first flange even when the first flange is pressed inwards e.g. by the ear canal during or after insertion of the eartip in said ear canal. This permits a better fit of the eartip to a wider range of ear canal dimension and, more importantly, without the contact line or area between the first flange and the second flange being broken. by preserving the integrity of contact line or area between the first flange and the second flange, the eartip maintains constant sound damping properties independently of the dimensions of the ear canal of the user.

[0025] According to example embodiments, the first flange and the second flange may comprise an elastomeric polymer.

[0026] This elastomeric polymer may be one or more polymers chosen from the group of thermoplastic elastomers (TPE), e.g. thermoplastic polyurethane (TPU), rubber like polymers like natural rubber, nitrile rubber, Ethylene-Propylene-Diene-Monomer (EPDM) rubbers, Acrylonitrile-butadiene-styrene (ABS), Polycarbonate / acrylonitrile butadiene styrene (PC-ABS), silicone rubbers (also referred to as silicone), Polyesters (PES), polyamide (PA, like PA6, PA6.6, PA6.10, and alike), Acrylic or Polymethyl Methacrylate (PMMA), Polycarbonate (PC), Polyethylene (PE), Polypropylene (PP), Polyethylene Terephthalate (PETE or PET), Polyvinyl Chloride (PVC), Polyoxymethylene (POM), and similar and combinations of two or more of these polymers. Silicone polymers are better tolerated by the end users having a more comfortable skin contact, and are therefore the preferred material for the eartip. The polymer may comprise additives such as organic or inorganic fillers. In order to modify the hardness of the silicone polymers, more or less silicone oils or gum, more or less or alternative fillers or more or less couplers or cross linking agents may be added, higher or lower molecular weight for the silicone polymers may be used, and / or the curing time of the polymer may be modified. Preferably, the first flange and the second flange of the eartip are flexible, and in this way promote uninterrupted contact between the first flange and the second flange at the contact line or area, better comfort and better conformity with the shape and size of the ear canal of the end user.

[0027] According to example embodiments, the first flange may further comprise a first inward wall of the first flange facing the second flange and wherein the second flange may further comprise a second outward wall of the second flange facing the first flange.

[0028] In this way, the first rim of the first flange and the second rim of the second flange are both open towards the distal end of the eartip, and thus, placing the contact line / area of the first flange and the second flange advantageously inside the wider section of the ear canal, when the eartip is inserted in that ear canal. This may further increase the contact area between the first flange and the ear canal, further reducing the pressure exerted by the former on the surface of the latter, greatly enhancing the comfort of the end user, while improving the sealing of the first flange against the ear canal of the user.

[0029] According to example embodiments, at least the first inward wall of the first flange facing the second flange and the second outward wall of the second flange facing the first flange may be provided with a friction-reducing coating, wherein the friction-reducing coating may comprise the following: antistatic UV surface treatment; and / or a layer of siloxane-based silicone coating.

[0030] Preferably, the second outward wall of the first flange may be provided with a friction-reducing coating. This coating advantageously eases the insertion and removal of the eartip into and from the ear canal. Given the sticky nature of freshly molded silicone, the friction-reducing coating advantageously may also eliminate the adhesion of debris or other contaminants to the eartip, providing greatly improved hygiene. More preferably, all the surfaces of the eartip are provided with a friction-reducing coating, most preferably said coating is a layer of siloxane-based silicone coating. This allows the first flange to slide effortlessly against the second flange, and in this way preventing any kinks or bending of any of the flanged at or near the contact line or area, which permits retaining airtightness at the contact line or area encompassing the air volume inside the at least one chamber. By preference, this coating may have a thickness between 0.05mm and 0.4mm, e.g. 0.05mm, 0.1mm, 0.15mm, 0.2mm, 0.25mm, 0.3mm, 0.35mm, 0.4mm. This siloxane based silicone coat may preferably comprise 30% of silica in its composition,. In this way, the friction reducing coating may demonstrate a non-sticky surface while still providing some grip, in particular when the surface of the friction reducing coating is in contact with the skin of the ear canal of the user, thus preventing the eartips from easily falling from the ears of the user. To further enhance the retention properties of the eartip, the friction reducing coating of the eartip may have an imprinted textured surface. To this end, a texture of VDI 21 was found to provide the ideal texture which may provide sufficient grip against the skin of the ear canal of the user while still feeling smooth and comfortable to the touch. However, textures between VDI 16 and VDI 26 may also be used if preferred by the user, e.g. if the eartip is to be used in warmer environments a coarser surface may be found to be necessary.

[0031] According to example embodiments, an angle between the first inward wall of the first flange and the second outward wall of the second flange may be comprised between 0° and 20.

[0032] This range of the an angle between the first inward wall of the first flange and the second outward wall of the second flange advantageously provide a balance between the pressure exerted by the second flange on the first inside wall of the first flange, and the size of the contact area between the contact area between the same. In this way, a cavity formed between the first inward wall of the first flange and the second outward wall of the second flange, as well as the contact area between said two flanges provide a more substantial sound damping performance. In order to provide adequate support under the first flange, the second flange may have a thickness comprised between 0.35mm and 0.45mm, by preference 0.4mm. Preferably, the angle between the first inward wall of the first flange and the second outward wall of the second flange is measured near the second rim, e.g. 1mm, 2mm or 3mm away from said second rim in a proximal direction, most preferably 1mm from the second rim in a proximal direction. This advantageously ensures that the angle between the first inward wall of the first flange and the second outward wall of the second flange may still fall within the desired range, even when the outer surface of the first flange is constrained by the ear canal of the user. By keeping this angle range for a wide range of ear canal dimensions, a continuous contact line or area is advantageously kept, which allows the maintenance of an immovable volume of air inside the chamber between the first flange and the second flange.

[0033] According to example embodiments, an angle between the first inward wall of the first flange and the stem may be comprised between 70° and 80°.

[0034] This angle between the first inward wall of the first flange and the stem provides an optimal balance between ease of insertion of the eartip in the ear canal, and wider range of ear canal dimensions to which the eartip can conform, while still being able to maintain the airtightness of the chamber between the first flange and the second flange.

[0035] According to example embodiments, the second flange may further comprise a second inward wall facing the stem; and wherein an angle between the second inward wall of the second flange and the stem may be comprised between 35° and 45°.

[0036] In this way, an optimal balance may be provided between the tension provided by the second flange against the first flange, and the volume of the a cavity formed between the first inward wall of the first flange and the second outward wall of the second flange. As a result, a more substantial sound damping performance may be obtained.

[0037] According to a second example aspect of the present disclosure, a method of manufacturing an eartip is provided, wherein the method comprises the steps of: forming an eartip structure comprising: ∘ a stem extending along an axial direction; ∘ a second flange extending radially and longitudinally from the stem, wherein the second flange comprises a second end extending around and coupled to the stem at a second axial coupling position along the axial direction; ∘ a first inverted flange extending radially and longitudinally from the stem, wherein the first inverted flange comprises a first end extending around and coupled to the stem at a first axial coupling position along the axial direction; and inverting the first inverted flange along the axial direction, thereby forming a first flange wherein: ∘ the first flange encompasses the second flange; ∘ the first flange and the second flange contact each other along at least one contact line encircling the stem at a contact position along the axial direction; and ∘ the second axial coupling position is comprised between the first axial coupling position and the contact position.

[0038] Hence, the method according to the second example aspect of the present disclosure may provide an ear plug according to the first example aspect of the present disclosure. The forming of the ear tip may preferably be performed by means of a mold, more preferably by injection molding. In this way, the eartips may more easily and economically be produced. By molding the first flange in an inverted position, the need for a complex mold is obviated, further reducing the initial cost of production while also making extraction of the formed eartips form the mold much easier and without the risk of tearing the delicate flanges of the eartip.

[0039] According to example embodiments, the method may further comprise the steps of: providing a mold for forming the eartip structure, wherein the mold may comprise an inner surface; coating at least the inner surface of the mold with a friction-reducing coating comprising the following: ∘ a layer of UV-curable layer of silicone rubber; and / or ∘ a layer of siloxane-based silicone coating; providing an elastomeric polymer in the mold, thereby forming the eartip structure.

[0040] For this purpose of providing a friction reducing coating, the mold being used may be a metal, ceramic and / or crystal mold. The mold used may have one shell, preferably more shells. The mold may have two shells wherein one of the shells is a transparent shell, possibly quartz, glass or ceramic. This mold with transparent shell is particularly suited for the application of a UV treatment to a layer of UV-curable silicone. In order to more fully apply a UV treatment to the surface of the eartip, all shells of the mold may be made of transparent quartz, glass or ceramic. Preferably, the second outward wall of the first flange may be provided with a fiction-reducing coat. More preferably, all the surfaces of the eartip are provided with a friction-reducing coating, most preferably said coating is a layer of siloxane-based silicone coating. By preference, this coating may have a thickness between 0.05mm and 0.4mm, e.g. 0.05mm, 0.1mm, 0.15mm, 0.2mm, 0.25mm, 0.3mm, 0.35mm, 0.4mm. A preferred embodiment of the method, in particular the step of coating at least the inner surface of the mold with a friction-reducing coating includes the application of a layer of siloxane-based silicone coating to the interior of the mold. This siloxane based silicone preferably comprises at least 20% silica, more preferably 22%, 24%, 26%, 28, most preferably 30% of silica in its composition. In this way, the friction reducing coating will retain a non-sticky surface while still provide some grip, in particular when the surface of said friction reducing coating is in contact with the skin of the ear canal of the user, thus preventing the eartips from easily falling from the ears of the user. To further enhance the retention properties of the eartip, the molds used are provided with a textured internal surface, which textured surface will imprint on the friction reducing coating. To this end, a texture of VDI 21 was found to provide the ideal texture which may provide sufficient grip against the skin of the ear canal of the user while still feeling smooth and comfortable to the touch. However, textures between VDI 16 and VDI 26 may also be used if preferred by the user, e.g. if the eartip is to be used in warmer environments a coarser surface may be found to be necessary.

[0041] It is understood that features from one of the aspects of the invention may be combined with one or more, even all features of one or more of the other aspects of the invention.

[0042] In general, when for a feature, reference is made to a range, the range is to be understood inclusive, unless explicitly mentioned differently.Brief Description of the Drawings

[0043] Fig. 1 schematically illustrates an example embodiment of an eartip according to the first aspect of the present disclosure; and Fig. 2 schematically illustrates an example embodiment of an eartip as obtained after the step of forming according to the second aspect of the present disclosure. Detailed Description of Embodiment(s)

[0044] Fig. 1 schematically illustrates an example embodiment of an eartip 1 according to the first aspect of the present disclosure. The eartip 1 is shown comprising a stem 300 extending along an axial direction 2, from which stem 300 a second flange 201 extends radially and longitudinally, wherein the second flange 201 comprises a second end 21 extending around and coupled to the stem 300 at a second axial coupling position 212 along the axial direction 2. The eartip 1 is shown further comprising a first flange 101 extending radially and longitudinally from the stem 300, wherein the first flange 101 comprises a first end 11 extending around and coupled to the stem 300 at a first axial coupling position 111 along the axial direction 2; wherein the first flange 101 encompasses the second flange 201. The first flange 101 and the second flange 201 are shown in contact each other along at least one contact line 40 encircling the stem 300 at a contact position 401 along the axial direction 2. This second axial coupling position 212 is comprised between the first axial coupling position 111 and the contact position 401. The first flange 101 further comprises a first rim 12 formed at a first rim position 121 along the axial direction 2 and being radially inwardly deflected. The second flange 201 further comprises a second rim 22 formed at a second rim position 221 along the axial direction 2. The second rim position 221 shown closer to the proximal end 31 along the axial direction 2 than the first rim position 121. The first flange 101 is shown with a visible taper wherein the thickness of the first flange 101 gradually reduces towards the first rim 12. The opposite distal end 32 is adapted to be coupled to an outer ear structure by means of second axial coupling position 212. In Fig. 1 the stem 300 is shown provided with a hollow channel along its entire length.

[0045] Fig. 2 schematically illustrates an example embodiment of an eartip 1 as obtained after the step of forming according to the second aspect of the present disclosure. The eartip 1 is shown comprising a stem 300 extending along an axial direction 2, from which stem 300 a second flange 201 extends radially and longitudinally, wherein the second flange 201 comprises a second end 21 extending around and coupled to the stem 300 at a second axial coupling position 212 along the axial direction 2. The eartip 1 is shown further comprising a first flange 101 a first inverted flange 501 extending radially and longitudinally from the stem 300, wherein the first inverted flange 501 comprises a first end 11 extending around and coupled to the stem 300 at a first axial coupling position 111 along the axial direction 2. This second axial coupling position 212 is comprised between the first axial coupling position 111 and the opposite distal end 32 of the stem.300 The first flange 101 further comprises a first rim 12 formed at a first rim position 121 along the axial direction 2 and being radially inwardly deflected. The first rim position 121 being shown proximally located relative to the first axial coupling position 111. The second flange 201 further comprises a second rim 22 formed at a second rim position 221 along the axial direction (2). The second rim position 221 shown closer to the proximal end 31 along the axial direction 2 than the first rim position 121. The first flange 101 is shown with a visible taper wherein the thickness of the first flange 101 gradually reduces towards the first rim 12. The opposite distal end 32 is adapted to be coupled to an outer ear structure by means of second axial coupling position 212. In Fig. 2 the stem 300 is shown provided with a hollow channel along its entire length. In the configuration shown in Fig. 2, the eartip 1 is ready for a step of inverting the first flange over the first axial coupling position 111 and towards the opposite distal end 32 of the stem 300 in order to rendered ready to be used as shown in Fig. 1.

[0046] Although the present concept has been illustrated by reference to specific embodiments, it will be apparent to those skilled in the art that the concept is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied with various changes and modifications without departing from the scope thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. In other words, it is contemplated to cover any and all modifications, variations or equivalents that fall within the scope of the basic underlying principles and whose essential attributes are claimed in this patent application. It will furthermore be understood by the reader of this patent application that the words "comprising" or "comprise" do not exclude other elements or steps, that the words "a" or "an" do not exclude a plurality, and that a single element, such as a computer system, a processor, or another integrated unit may fulfil the functions of several means recited in the claims. Any reference signs in the claims shall not be construed as limiting the respective claims concerned. The terms "first", "second", third", "a", "b", "c", and the like, when used in the description or in the claims are introduced to distinguish between similar elements or steps and are not necessarily describing a sequential or chronological order. Similarly, the terms "top", "bottom", "over", "under", and the like are introduced for descriptive purposes and not necessarily to denote relative positions. It is to be understood that the terms so used are interchangeable under appropriate circumstances and embodiments of the invention are capable of operating according to the present invention in other sequences, or in orientations different from the one(s) described or illustrated above.

Examples

Embodiment Construction

[0044]Fig. 1 schematically illustrates an example embodiment of an eartip 1 according to the first aspect of the present disclosure. The eartip 1 is shown comprising a stem 300 extending along an axial direction 2, from which stem 300 a second flange 201 extends radially and longitudinally, wherein the second flange 201 comprises a second end 21 extending around and coupled to the stem 300 at a second axial coupling position 212 along the axial direction 2. The eartip 1 is shown further comprising a first flange 101 extending radially and longitudinally from the stem 300, wherein the first flange 101 comprises a first end 11 extending around and coupled to the stem 300 at a first axial coupling position 111 along the axial direction 2; wherein the first flange 101 encompasses the second flange 201. The first flange 101 and the second flange 201 are shown in contact each other along at least one contact line 40 encircling the stem 300 at a contact position 401 along the axial directi...

Claims

1. An eartip (1) comprising: - a stem (300) extending along an axial direction (2); - a second flange (201) extending radially and longitudinally from the stem (300), wherein the second flange (201) comprises a second end (21) extending around and coupled to the stem (300) at a second axial coupling position (212) along the axial direction (2); and - a first flange (101) extending radially and longitudinally from the stem (300), wherein the first flange (101) comprises a first end (11) extending around and coupled to the stem (300) at a first axial coupling position (111) along the axial direction (2); wherein the first flange (101) encompasses the second flange (201); wherein the first flange (101) and the second flange (201) contact each other along at least one contact line (40) encircling the stem (300) at a contact position (401) along the axial direction (2); and wherein the second axial coupling position (212) is comprised between the first axial coupling position (111) and the contact position (401).

2. The eartip according to claim 1, wherein: - the stem (300) comprises a proximal end (31) and an opposite distal end (32); - the first flange (101) further comprises a first rim (12) formed at a first rim position (121) along the axial direction (2) and being radially inwardly deflected; - the second flange (201) further comprises a second rim (22) formed at a second rim position (221) along the axial direction (2); and wherein the second rim position (221) is closer to the proximal end (31) along the axial direction (2) than the first rim position (121).

3. The eartip (1) according to claim 2, wherein a thickness of the first flange (101) at the first end (11) is 5% to 45% larger than a thickness of the first flange (101) at the first rim (12).

4. The eartip (1) according to any of the preceding claims, wherein the stem (300) extends less along the axial direction (2) than the first flange (101) and the second flange (201).

5. The eartip (1) according to any of the preceding claims, wherein the opposite distal end (32) is adapted to be coupled to an outer ear structure.

6. The eartip (1) according to any of the preceding claims, wherein the first flange (101) and the second flange (201) contact each other along a contact surface, wherein the contact surface encloses the stem (300).

7. The eartip (1) according to any of the preceding claims, wherein a diameter of the first flange (101) at the first rim position (121) is smaller than a diameter of the second flange (201) at the second rim position (221).

8. The eartip (1) according to any of the preceding claims, wherein the first flange (101) and the second flange (201) comprise an elastomeric polymer.

9. The eartip (1) according to any of the preceding claims, wherein the first flange (101) further comprises a first inward wall of the first flange (101) facing the second flange (201) and wherein the second flange (201) further comprises a second outward wall of the second flange (201) facing the first flange (101).

10. The eartip (1) according to claim 9, wherein at least the first inward wall of the first flange (101) facing the second flange (201) and the second outward wall of the second flange (201) facing the first flange (101) are provided with a friction-reducing coating, wherein the friction-reducing coating comprises the following: - antistatic UV surface treatment; and / or - a layer of siloxane-based silicone coating.

11. The eartip (1) according to any one of the claims 9 or 10, wherein an angle between the first inward wall of the first flange (101) and the second outward wall of the second flange (201) is comprised between 0° and 20°.

12. The eartip (1) according to any one of the claims 9 to 11, wherein an angle between the first inward wall of the first flange and the stem is comprised between 70° and 80°.

13. The eartip (1) according to any one of the claims 9 to 12, wherein the second flange (201) further comprises a second inward wall facing the stem (300); and wherein an angle between the second inward wall of the second flange (201) and the stem (300) is comprised between 35° and 45°.

14. A method of manufacturing an eartip (1), wherein the method comprises the steps of: - forming an eartip structure (3) comprising: ∘ a stem (300) extending along an axial direction (2); ∘ a second flange (201) extending radially and longitudinally from the stem (300), wherein the second flange (201) comprises a second end (21) extending around and coupled to the stem (300) at a second axial coupling position (212) along the axial direction (2); ∘ a first inverted flange (501) extending radially and longitudinally from the stem (300), wherein the first inverted flange (501) comprises a first end (11) extending around and coupled to the stem (300) at a first axial coupling position (111) along the axial direction (2); and - inverting the first inverted flange (501) along the axial direction (2), thereby forming a first flange (101) wherein: ∘ the first flange (101) encompasses the second flange (201); ∘ the first flange (101) and the second flange (201) contact each other along at least one contact line (40) encircling the stem (300) at a contact position (401) along the axial direction (2); and ∘ the second axial coupling position (212) is comprised between the first axial coupling position (111) and the contact position (401).

15. The method according to claim 14, wherein the method further comprises the steps of: - providing a mold for forming the eartip structure (3), wherein the mold comprises an inner surface; - coating at least the inner surface of the mold with a friction-reducing coating comprising the following: ∘ a layer of UV-curable layer of silicone rubber; and / or ∘ a layer of siloxane-based silicone coating; - providing an elastomeric polymer in the mold, thereby forming the eartip structure (3).

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