Eartips and related devices and methods

Abstract

To provide ear tips and related devices and methods.SOLUTION: An ear tip 104 includes a body 120 configured to be mounted on an earbud. The body 120 includes a first end 122, a second end 124 opposite the first end 122, and an inner wall 126 extending between the first end 122 and the second end 124. The inner wall 126 defines and surrounds a hollow passage 128 configured to conduct sound waves. The body 120 also includes an outer wall 130 that is connected to the inner wall 126 at the first end 122 and extends away from the inner wall 126 toward the second end 124. The inner wall 126 has an oblong cross-sectional shape that is configured to accommodate a corresponding nozzle on the earbud. The inner wall includes a ring 132 that is formed of a rigid material and engages and conforms to the oblong shape of the nozzle, which inhibits improper mounting and rotation of the ear tip 104 relative to the nozzle.SELECTED DRAWING: Figure 3C

Description

[Background technology]

[0001] FIELD OF THE DISCLOSURE The present disclosure relates to eartips and related devices and methods.

[0002] Modern in-ear headphones offer active noise reduction, which helps reduce ambient noise in a user's ear canal. Active noise reduction is generally achieved through the use of analog circuitry or digital signal processing. Adaptive algorithms are designed to analyze the waveform of the ambient noise and then, based on a specific algorithm, generate a signal that phase-shifts or inverts the polarity of the original signal. This inverted signal (opposite phase) is then amplified, and a transducer (speaker) generates sound waves that are directly proportional to the amplitude of the original waveform, creating destructive interference. This effectively reduces the perceived volume of the noise.

[0003] An important complement to this active noise reduction is the passive attenuation of noise provided by a material that seals the user's ear canal. In that regard, many modern in-ear headphones include compliant eartips, typically made from low-durometer silicone. These eartips form an acoustic seal with the user's ear canal and act as a physical barrier to the transmission of ambient noise. The low-durometer silicone provides comfort because it is soft and compliant, which helps ensure a good acoustic seal with the user's ear canal.

[0004] While active noise reduction is highly effective at lower frequencies (e.g., 20 Hz to 1 kHz), headphones rely heavily on passive attention to attenuate (reduce) higher frequency noise (e.g., above 1 kHz). Unfortunately, the low-durometer silicone commonly used in eartips is not particularly good at attenuating high frequencies in the 1 kHz to 1.5 kHz range. This can allow unwanted noise to pass through the eartip material and into the user's ear canal.

[0005] The present disclosure relates to an eartip for headphones having improved passive damping. The present disclosure also relates to an eartip designed to mate with an oval nozzle and configured to resist rotation about the nozzle when mated to the nozzle. Summary of the Invention

[0006] All embodiments and features mentioned below can be combined in any technically possible manner.

[0007] In one embodiment, the eartip includes a body configured to be attached to an earbud. The body includes a first end, a second end opposite the first end, and an inner wall extending between the first and second ends. The inner wall defines and surrounds a hollow passage configured to conduct sound waves. The body also includes an outer wall connected to the inner wall at the first end and extending away from the inner wall toward the second end. The inner wall has an elongated cross-sectional shape configured to accommodate a corresponding nozzle on the earbud. The inner wall is formed of a rigid material and includes a ring that engages and conforms to the elongated shape of the nozzle, preventing improper attachment of the eartip to the nozzle and preventing rotation of the eartip relative to the nozzle when the eartip is attached to the nozzle.

[0008] Implementations may include one or any combination of the following features.

[0009] In some implementations, the inner wall further includes a high durometer compliant material that defines at least a portion of an extension that extends between the nozzle and the first end of the eartip.

[0010] In some implementations, the outer wall is molded around a high durometer compliant material and the outer wall is formed from a lower durometer compliant material.

[0011] In some cases, the ring includes at least one C-shaped member having at least one gap, and the high durometer compliant material is molded around the ring to fill the gap.

[0012] In some cases, the ring includes a pair of C-shaped members disposed with a pair of gaps between the members, and the high durometer compliant material fills both gaps.

[0013] In some cases, the high durometer compliant material defines a retaining member configured to engage a mating retaining member on the nozzle.

[0014] In a particular example, the ring defines a recess extending around the inner surface of the inner wall and is configured to receive an O-ring seated in a corresponding recess formed in and extending around the outer surface of the nozzle.

[0015] In some implementations, the inner wall also includes an extension extending between the nozzle and the first end of the eartip, and the outer wall and extension are at least partially formed from a viscoelastic material having frequency reinforcement behavior.

[0016] In certain implementations, the extension and outer wall are formed from a styrene-based TPE having viscoelastic properties (eg, A9 TPE).

[0017] Optionally, the exterior surface of the outer wall is treated with a surface treatment selected from electron beam treatment and photoionization to improve sebum resistance.

[0018] In some cases, the exterior surface of the exterior wall has a soft-touch coating.

[0019] In some examples, the soft touch coating is a 50% poly(styrene-isobutylene-styrene) (SIBS) block copolymer / 50% silicone (wt / wt) soft touch coating.

[0020] In certain instances, the viscoelastic material is a composition that includes an elastomer and one or more phase change materials that have the ability to change phase from a solid state to a liquid state at a predetermined phase change temperature.

[0021] In some implementations, the predetermined phase change temperature is between about 25°C and about 35°C.

[0022] In certain implementations, the composition has a hardness of about 5 Shore A to about 50 Shore A, and the amount of phase change material in the composition is about 10% to about 40% by weight.

[0023] In another aspect, an eartip includes a body configured to be attached to an earbud. The body includes a first end, a second end opposite the first end, and an inner wall extending between the first and second ends. The inner wall defines and surrounds a hollow passage configured to conduct sound waves. The body also includes an outer wall connected to the inner wall at the first end and extending away from the inner wall toward the second end. The inner wall is configured to engage with a nozzle on the earbud. The inner wall includes an extension extending between the nozzle and the first end of the eartip, and the outer wall and extension are at least partially formed from a viscoelastic material, including a styrene-based TPE having viscoelastic properties (e.g., A9 TPE).

[0024] Implementations may include one or any combination of the above and / or below features.

[0025] In some implementations, the exterior surface of the outer wall is treated with a surface treatment selected from electron beam treatment and photoionization to improve sebum resistance.

[0026] In certain implementations, the exterior surface of the exterior wall has a soft-touch coating.

[0027] In some cases, the soft touch coating is a 50% SIBS / 50% silicone (wt / wt) soft touch coating.

[0028] In certain cases, the viscoelastic material includes a composition comprising a styrenic TPE having viscoelastic properties and one or more phase change materials capable of changing phase from a solid state to a liquid state at a predetermined phase change temperature.

[0029] In some examples, the predetermined phase change temperature is between about 25°C and about 35°C.

[0030] In particular examples, the composition has a hardness of about 5 Shore A to about 50 Shore A, and the amount of phase change material in the composition is about 10% to about 40% by weight.

[0031] In some implementations, the viscoelastic material defines a retaining member configured to engage a mating retaining member on the nozzle.

[0032] In certain implementations, the inner wall also includes a ring formed of a hard plastic and configured to engage the nozzle.

[0033] In some cases, the ring defines a recess extending around the inner surface of the inner wall and is configured to receive an O-ring seated in a corresponding recess formed in and extending around the outer surface of the nozzle.

[0034] In certain cases, the styrenic TPE having viscoelastic properties is an A9 TPE.

[0035] Another aspect features an eartip including a body configured to be attached to an earbud. The body includes a first end, a second end opposite the first end, and an inner wall formed of a first material having a first durometer. The inner wall extends between the first end and the second end. The inner wall defines and encloses a hollow passage configured to conduct sound waves. The body also includes an outer wall formed of a second material having a second durometer less than the first durometer. The outer wall is connected to the inner wall at the first end and extends away from the inner wall toward the second end. The inner wall has an elongated cross-sectional shape configured to accommodate a corresponding nozzle on the earbud. The inner wall defines a retention mechanism having two ends and two side portions connecting them. The thickness of the side portions is different from the thickness of the ends. The retention feature engages and fits with a complementary retention feature on the nozzle to prevent improper attachment of the eartip to the nozzle and to prevent rotation of the eartip relative to the nozzle once the eartip is attached to the nozzle. [Brief explanation of the drawings]

[0036] [Figure 1A] FIG. [Figure 1B] FIG. 1B is an exploded front perspective view of the earpiece of FIG. 1A. [Figure 2] FIG. 1B is a side cross-sectional view of the earpiece of FIG. 1A. [Figure 3A] FIG. 1 is a front perspective view of a first embodiment of an eartip according to the present disclosure. [Figure 3B] FIG. 3B is a rear perspective view of the eartip of FIG. 3A. [Figure 3C] FIG. 3B is a side cross-sectional view of the eartip of FIG. 3A. [Figure 4] 3B is a side cross-sectional view of the eartip of FIG. 3A attached to the nozzle of an earbud. [Figure 5] FIG. 10 is a rear perspective view of a second embodiment of an eartip according to the present disclosure. [Figure 6A] FIG. 10 is a front perspective view of a third embodiment of an eartip according to the present disclosure. [Figure 6B] FIG. 6B is a rear perspective view of the eartip of FIG. 6A. [Figure 6C] FIG. 6B is a side cross-sectional view of the eartip of FIG. 6A. [Figure 6D] 6B is a side cross-sectional view of the eartip of FIG. 6A attached to the nozzle of an earbud. [Figure 7A] FIG. 10 is a front perspective view of a fourth embodiment of an eartip according to the present disclosure. [Figure 7B] FIG. 7B is a rear perspective view of the eartip of FIG. 7A. [Figure 7C] FIG. 7B is a side cross-sectional view of the eartip of FIG. 7A. [Figure 7D] 7B is a side cross-sectional view of the eartip of FIG. 7A attached to the nozzle of an earbud. [Figure 8A] FIG. 10 is a front perspective view of a fifth embodiment of an eartip according to the present disclosure. [Figure 8B] FIG. 8B is a rear perspective view of the eartip of FIG. 8A. [Figure 8C] FIG. 8B is a side cross-sectional view of the eartip of FIG. 8A. [Figure 8D] 8B is a side cross-sectional view of the eartip of FIG. 8A attached to the nozzle of an earbud. [Figure 9A] FIG. 10 is a front perspective view of a sixth embodiment of an eartip according to the present disclosure. [Figure 9B] FIG. 9B is a rear perspective view of the eartip of FIG. 9A. [Figure 9C] FIG. 9B is a side cross-sectional view of the eartip of FIG. 9A. [Figure 9D] 9B is a side cross-sectional view of the eartip of FIG. 9A attached to the nozzle of an earbud. [Figure 10A] FIG. 10 is a front perspective view of a seventh embodiment of an eartip according to the present disclosure. [Figure 10B] FIG. 10B is a rear perspective view of the eartip of FIG. 10A. [Figure 10C] FIG. 10B is a side cross-sectional view of the eartip of FIG. 10A taken along the minor axis of the eartip. [Figure 10D] 10B is a cross-sectional side view of the eartip of FIG. 10A along the minor axis of the eartip, shown attached to the nozzle of an earbud. [Figure 10E]FIG. 10B is a side cross-sectional view of the eartip of FIG. 10A taken along the long axis of the eartip. [Figure 10F] 10B is a cross-sectional side view of the eartip of FIG. 10A along the long axis of the eartip, shown attached to the nozzle of an earbud. [Figure 11] FIG. 10B is a front perspective view of an earbud nozzle for use with the eartip of FIG. 10A.

[0037] Commonly labeled components in the figures are considered to be substantially equivalent components for illustrative purposes, and redundant descriptions of those components are omitted for clarity. Numerical ranges and values ​​set forth according to various implementations are merely examples of such ranges and values ​​and are not intended to limit these implementations. In some cases, the term "about" is used to modify a value; in these cases, these values ​​may refer to a margin of error, such as measurement error, which may range up to 1 to 5 percent. DETAILED DESCRIPTION OF THE INVENTION

[0038] 1A, 1B, and 2 illustrate an exemplary earpiece 100 constructed in accordance with the present disclosure. The earpiece 100 includes an earbud 102 and an eartip 104. The earbud 102 also includes a housing 106 defining a nozzle 108 configured to couple to the eartip 104. The housing 106 may be formed, for example, by molding, from a rigid plastic such as acrylonitrile butadiene styrene (ABS), polycarbonate / acrylonitrile butadiene styrene (PCB / ABS), polyetherimide (PEI), or stereolithography (SLA) resin. The housing 106 defines a cavity 110 in which an electro-acoustic transducer 111 (also called a "speaker" or "receiver" or "driver"), a battery 114, and electronic circuitry 116 may be disposed. The cavity 110 is acoustically coupled to an acoustic passage 112 within the nozzle 108, such that an electro-acoustic transducer 111 may be acoustically coupled to a user's ear when an earpiece is attached, for example. The housing 106 may also support one or more microphones 118.

[0039] As shown in FIG. 1B, the nozzle 108 has an elongated cross-sectional shape, such as an oval, an ellipse, a racetrack shape (with parallel sides and rounded ends extending between them, also known as a "stadium"), or an elongated shape with rounded ends and curved splines connecting them, as shown in FIG. 1B. Here, "cross-section" or "cross-sectional" should be understood to be perpendicular to the central axis of the nozzle. This is expected to fit a user's ear canal better than a simple circular cross-section. The earpiece 100 may also include a stabilizing means to assist in holding the earpiece 100 in a user's ear.

[0040] 3A-3D, the eartip 104 is configured to fit at least partially within a person's ear canal. The eartip 104 includes a body 120 configured to be mounted on the earbud 102. The body 120 includes a first end 122 and a second end 124 opposite the first end 122. The body 120 further includes an inner wall 126 extending between the first end 122 and the second end 124. The inner wall 126 defines and surrounds a hollow passage 128 that may be configured to conduct sound waves. The inner wall 126 has an elongated cross-sectional shape, such as an ellipse, an oval, a racetrack shape (with parallel sides and rounded ends extending between the parallel sides, also known as a "stadium"), or an elongated shape with rounded ends and curved splines connecting them, as shown in FIG. 3B. Here, "cross section" or "cross section" should be understood to be perpendicular to the central axis of the inner wall 126. The body 120 also includes an outer wall 130 connected to the inner wall 126 at a first end 122. The outer wall 130 extends away from the inner wall 126 toward a second end 124. In the illustrated example, the outer wall 130 is dome-shaped; however, other shapes, such as a cone, are also contemplated. As shown in FIG. 3C , the outer wall 130 extends beyond the second end 124. In alternative implementations, the outer wall 130 may extend toward, but not necessarily reach, the second end 124.

[0041] The embodiment shown in Figures 3A-3C uses three different materials of varying hardness to form the eartip 104, which is formed in a three-shot molding process. The first material, a hard plastic (e.g., glass-filled polyimide), is used to provide a ring 132 that engages the nozzle 108 to prevent rotation. In this regard, the ring 132 conforms to the elongated shape of the nozzle 108, thereby preventing improper attachment of the eartip 104 and preventing rotation of the eartip 104 relative to the nozzle 108 once the eartip 104 is attached to the nozzle 108. As shown in Figure 4, the ring 132 may be C-shaped with a gap 134 that allows some compliance, allowing the ring 132 to accommodate the nozzle 108.

[0042] The second material is a high durometer compliant material, such as high durometer silicone, e.g., 60 Shore A to 80 Shore A silicone, e.g., 70 Shore A silicone, that is molded around the ring 132. The ring 132 and the second material together form the inner wall 126. The second material extends around the inner surface of the inner wall 126 and defines a retention feature 134, e.g., a protrusion, configured to engage with a complementary retention feature 136, e.g., a recess, defined by and extending around the outer surface of the nozzle 108. The engagement of the retention features 134, 136 helps to retain the eartip 104 on the nozzle 108 and provides a good acoustic seal between the earbud 102 and the eartip 104.

[0043] The second material also fills the gap 134 in the ring 132, thereby allowing some compliance to fit over the nozzle 108 and allowing the ends of the ring 132 to be displaced relative to each other while providing a closed shape (closed ring) to the second end 124 of the eartip 104.

[0044] The second material also defines at least a portion of an extension 138 that extends between the nozzle 108 and the first end 122 of the eartip 104. The use of a high durometer material in this region provides improved passive attenuation performance over prior art eartips that used low durometer silicone in this region, although low durometer silicone would pass excessive noise.

[0045] Finally, the outer wall 130 is molded around the high durometer material. For comfort, the outer wall 130 is formed of a low durometer material, such as low durometer silicone, e.g., 10 Shore A to 30 Shore A silicone, e.g., 20 Shore A silicone. The outer wall 130 is the portion of the eartip that contacts and conforms to the user's ear canal, forming an acoustic seal therebetween. As shown in FIG. 3A, the outer wall 130 has an elongated cross-sectional shape, such as an oval, an ellipse, a racetrack shape (with parallel sides and rounded ends extending between them, also known as a "stadium"), or a dome shape with rounded ends and curved splines connecting them, as shown in FIG. 3A. Here, "cross-section" or "cross-section" should be understood to be perpendicular to the central axis of the dome / outer wall 130.

[0046] The eartip 104 may be formed in a three-shot molding process, where the ring 132 is formed in a first molding step, followed by the remainder of the inner wall 126 in a second molding step, and finally the outer wall 130 in a third molding step.

[0047] 5 shows an alternative implementation in which ring 132 is formed from two separate C-shaped members, both formed from a hard plastic material (e.g., glass-filled polyimide) with a pair of gaps 500 between them, which are filled with a second material during the molding process.

[0048] 6A-6D show another implementation of an eartip 604 including a body 620 configured to attach to an earbud (e.g., earbud 102 of FIGS. 1A and 1B). The body 620 includes a first end 622 and a second end 624 opposite the first end 622. The body 620 further includes an inner wall 626 extending between the first end 622 and the second end 624. The inner wall 626 defines and encloses a hollow passage 628 that can be configured to conduct sound waves. The inner wall 626 has an elongated cross-sectional shape, such as an ellipse, an oval, a racetrack shape (with parallel sides and rounded ends extending between the parallel sides, also known as a "stadium"), or an elongated shape with rounded ends and curved splines connecting them, as shown in FIG. 6B. Here, a "cross-section" or "cross-sectional" should be understood to be perpendicular to the central axis of the inner wall 626. The body 620 also includes an outer wall 630 connected to the inner wall 626 at a first end 622. The outer wall 630 extends away from the inner wall 626 toward a second end 624. In the illustrated example, the outer wall 630 is dome-shaped; however, other shapes, such as a cone, are also contemplated. As shown in FIG. 6C , the outer wall 630 extends beyond the second end 624. In alternative implementations, the outer wall 630 may extend toward, but not necessarily reach, the second end 624.

[0049] 6A-6D uses three different materials of varying hardness to form the eartip 604, which is formed in a three-shot molding process. The first material, a hard plastic (e.g., glass-filled polyimide), is used to provide a ring 632 that engages the nozzle 108 to prevent rotation. In this regard, the ring 632 conforms to the elongated shape of the nozzle 108, thereby preventing improper attachment of the eartip 604 when it is attached to the nozzle 108.

[0050] 6C and 6D , the ring 632 defines a recess 634 (e.g., annular groove) that extends around the inner surface of the inner wall 626 and is configured to receive an O-ring 635 (e.g., a rubber O-ring) that seats in a corresponding recess 136 (e.g., annular groove) formed in and extending around the outer surface of the nozzle 108. In this implementation, engagement of the retention features 634, 136 with the O-ring 635 helps to retain the eartip 604 on the nozzle 108 and also provides a good acoustic seal between the earbud 102 and the eartip 604.

[0051] 6C and 6D, the ring 632 can also define a lip 637 that overlaps the end of the nozzle 108. The lip 637 can support a wax guard 638, such as a screen, that can be heat staked to the lip 637. This can be an alternative to, or in addition to, a wax guard 640 (FIG. 6D) on the nozzle 108 itself.

[0052] The second material is a high durometer compliant material, such as a high durometer silicone, e.g., 60 Shore A to 80 Shore A silicone, e.g., 70 Shore A silicone, that is molded around the ring 632. The ring 632 and the second material together form the inner wall 626. The second material defines at least a portion of an extension 642 that extends between the nozzle 108 and the first end 622 of the eartip 604. The use of a high durometer material in this region provides improved passive attenuation performance over prior art eartips that used low durometer silicone in this region, whereas low durometer silicone would pass excessive noise.

[0053] Finally, an outer wall 630 is molded around the high durometer material. The outer wall 630 is formed from a low-durometer compliant material, such as a low-durometer silicone, e.g., 10 Shore A to 30 Shore A silicone, e.g., 20 Shore A silicone, for comfort. The outer wall 630 is the portion of the eartip that contacts and conforms to the user's ear canal, forming an acoustic seal therebetween. As shown in FIG. 6A, the outer wall 130 has an elongated cross-sectional shape, such as an ellipse, an oval, a racetrack shape (with parallel sides and rounded ends extending between them, also known as a "stadium"), or a dome shape with an elongated shape having rounded ends and curved splines connecting them, as shown in FIG. 6A. Here, "cross-section" or "cross-sectional" should be understood to be perpendicular to the central axis of the dome / outer wall 630.

[0054] 7A-7D show yet another implementation of an eartip 704 including a body 720 configured to attach to an earbud (e.g., earbud 102 of FIGS. 1A and 1B). The body 720 includes a first end 722 and a second end 724 opposite the first end 722. The body 720 further includes an inner wall 726 extending between the first end 722 and the second end 724. The inner wall 726 defines and encloses a hollow passage 728 that can be configured to conduct sound waves. The inner wall 726 has an elongated cross-sectional shape, such as an ellipse, an oval, a racetrack shape (with parallel sides and rounded ends extending between the parallel sides, also known as a "stadium"), or an elongated shape with rounded ends and curved splines connecting them, as shown in FIG. 7B. Here, "cross-section" or "cross-sectional" should be understood to be perpendicular to the central axis of the inner wall 726. The body 720 also includes an outer wall 730 connected to the inner wall 726 at a first end 722. The outer wall 730 extends away from the inner wall 726 toward a second end 724. In the illustrated example, the outer wall 730 is dome-shaped. However, other shapes, such as a cone, are also contemplated.

[0055] The implementation shown in Figures 7A-7D utilizes a viscoelastic material with frequency-reinforcing behavior, such as a styrenic thermoplastic elastomer (TPE) with viscoelastic properties, e.g., A9 TPE. A suitable A9 thermoplastic elastomer is available under the tradename GLS™, product number LC AB5-741, from Avient (formerly PolyOne), McHenry, Illinois. The viscoelastic material forms the outer wall 730 and at least a portion of the inner wall 726, including at least a portion of the extension 742 extending between the nozzle 108 and the first end 722 of the eartip 704. The use of a material with frequency-reinforcing behavior in this extension region provides improved passive damping performance in the 1 kHz to 1.5 kHz frequency range over prior art eartips that use low-durometer silicone in this region, although low-durometer silicone passes excessive noise. Because the material is viscoelastic, it has damping properties. It helps to attenuate impacts, shocks, and vibrations, and also aids in stability. Other suitable viscoelastic materials are described and claimed in US Pat. No. 10,623,846, entitled "Earpiece Employing Viscoelastic Materials," the complete disclosure of which is incorporated herein by reference.

[0056] For example, in some cases, the viscoelastic material may comprise a composition including one or more elastomers, the composition having a low frequency modulus metric (Mlf) of about 0.5 to about 1, a high frequency modulus metric (Mhf) of about 0.5 to about 1, and a glass transition temperature (Tg) of about -25°C to about 30°C. At least one of the one or more elastomers may be polynorbornene, polyurethane, styrenic thermoplastic elastomer, butyl rubber, acrylic, thermoplastic vulcanizate, nitrile rubber, or the like. At least one of the one or more elastomers may be polynorbornene. The polynorbornene may have a density of about 0.8 to about 1.2 kg / dm3, a hardness of about 10 to about 20 Shore A, and a tensile strength of about 2 to about 8 MPa. The composition may include polynorbornene, antioxidants, UV stabilizers, curing agents, inhibitors, plasticizers, fillers, and the like. The Tg may be about 5°C to about 30°C. Tg may be about 20° C. to about 30° C. Tg may be about 5° C. to about 25° C. Mhf may be about 0.7 to about 1. Mlf may be about 0.7 to about 1. The product of Mhf and Mlf may be about 0.5 to about 1.

[0057] Viscoelastic materials, particularly TPEs, can be vulnerable to sebum. In that regard, the outer surface of the eartip 704, e.g., the outer surface of at least the outer wall 730, may be treated with a surface treatment, such as electron beam treatment or photoionization, to form a crosslinked matrix within the outer layer of the eartip 704, such that the outer layer has a lower affinity for sebum than the inner layer (or untreated area(s)) of the eartip 704. Additional details regarding surface treatments are described and claimed in U.S. Pat. No. 1,0856,069, entitled "Sebum Resistance Enhancement for Wearable Devices," the complete disclosure of which is incorporated herein by reference.

[0058] What electron beam processing does to TPE is a curing process. Once the TPE is formed into its desired shape, electron beam processing creates chemical crosslinks in the material, which converts it to a silicone-like state, providing excellent sebum and chemical resistance. This aids in sebum resistance and unlocks the ability to add a soft-touch top coat over it. Electron beam processing can also provide improved performance in many tests, including thermal shock.

[0059] In some implementations, the eartip 704, at least the outer wall 730, may be treated with a soft-touch coating, such as that described and claimed in U.S. Patent Application No. 17 / 232,479, entitled "Soft Touch Material," filed April 16, 2021, the full disclosure of which is incorporated herein by reference. For example, the TPE forming the outer wall 730 may be treated with a 50% poly(styrene-isobutylene-styrene) (SIBS) block copolymer / 50% silicone (wt / wt) soft-touch coating.

[0060] As mentioned above, electron beam processing can allow for the application of a soft-touch top coat without damaging the part. The top coat can be applied via spray and then cured. In the process of applying the top coat, the part (ear tip 704) is stressed with a solvent, which is then cured at an elevated temperature. All of this can stress the part. Electron beam processing crosslinks the part, increasing its resistance to solvents and temperature.

[0061] The soft-touch coating can be applied anywhere a user is likely to touch. The soft-touch top coat provides a premium finish and aids in sealing and initial comfort. The soft-touch top coat can also help with dust protection, as A9 TPE materials tend to collect a lot of dust.

[0062] Viscoelastic materials may also include cooling and sensation-inducing materials, such as those described and claimed in U.S. Patent No. 10,531,174, entitled "Earpiece Employing Cooling and Sensation Inducing Materials," the complete disclosure of which is incorporated herein by reference. For example, the viscoelastic material may include a composition including an elastomer, e.g., a styrene-based TPE having viscoelastic properties, such as A9 TPE, and one or more phase change materials capable of changing phase from a solid state to a liquid state at a predetermined phase change temperature, e.g., from about 25°C to about 35°C. The composition may have a hardness of from about 5 Shore A to about 50 Shore A, and the amount of phase change material in the composition is from about 10% to about 40% by weight.

[0063] 7A-7D, the viscoelastic material extends around the inner surface of the inner wall 726 and defines a retention feature 734, e.g., a protrusion, configured to engage with a complementary retention feature 136, e.g., a recess, defined by and extending around the outer surface of the nozzle 108. The engagement of the retention features 734, 136 helps to retain the eartip 704 on the nozzle 108 and also provides a good acoustic seal between the earbud 102 and the eartip 704.

[0064] As shown in FIGS. 7B-7D , the inner wall 726 is a ring 132 formed of a hard plastic material, such as glass-filled polyimide. The ring 726 is configured to engage the nozzle 108 to prevent rotation. In this regard, the ring 732 conforms to the elongated shape of the nozzle 108, thereby preventing improper attachment of the eartip 104 when the eartip is attached to the nozzle 108. That is, the ring 732 ensures that the tip will only fit onto the nozzle 108 when properly oriented relative to the nozzle 108, and the elongated cross-sectional shape of the ring 732 and the nozzle 108, along with the rigidity of the ring 732, help ensure that the eartip 704 cannot rotate around the nozzle 108 once attached. As shown in FIG. 7B , the ring 732 can be an oval, e.g., racetrack-shaped, closed form (e.g., a closed loop). Alternatively, the ring 732 can be an open form, such as a C-shape, with a gap that allows some compliance, allowing the ring 732 to accommodate the nozzle 108. The gap can be filled with a viscoelastic material during the molding process in which the eartip 704 is formed. In some cases, the ring 732 can be formed of two separate C-shaped members, as shown in FIG. 5. In the embodiment of FIGS. 7A-7D, the ring 732 and the viscoelastic material together form the inner wall 726.

[0065] The eartip 704 may be formed in a two-shot molding process in which the ring 732 is formed first in a first molding step, and then the remainder of the eartip 704 (i.e., the remainder of the inner wall 726 and outer wall 730) is formed in a second molding step.

[0066] 8A-8D show another implementation of an eartip 804 that includes a body 820 configured to attach to an earbud (e.g., earbud 102 of FIGS. 1A and 1B). The body 820 includes a first end 822 and a second end 824 opposite the first end 822. The body 820 further includes an inner wall 826 extending between the first end 822 and the second end 824. The inner wall 826 defines and encloses a hollow passage 828 that can be configured to conduct sound waves. The inner wall 826 has an elongated cross-sectional shape, such as an ellipse, an oval, a racetrack shape (with parallel sides and rounded ends extending between the parallel sides, also known as a "stadium"), or an elongated shape with rounded ends and curved splines connecting them, as shown in FIG. 8B. Here, a "cross-section" or "cross-sectional" should be understood to be perpendicular to the central axis of the inner wall 826. The body 820 also includes an outer wall 830 connected to the inner wall 826 at a first end 822. The outer wall 830 extends away from the inner wall 826 toward a second end 824. In the illustrated example, the outer wall 830 is dome-shaped. However, other shapes, such as a cone, are also contemplated. As shown in FIG. 8C , the outer wall 830 extends beyond the second end 824. In alternative implementations, the outer wall 830 may extend toward, but not necessarily reach, the second end 824.

[0067] The implementation shown in Figures 8A-8D also utilizes a viscoelastic material with frequency reinforcement behavior, such as a styrenic TPE with viscoelastic properties, e.g., A9 TPE, which may include any of the surface treatments or compounds described above with respect to Figures 7A-7D.

[0068] 8B-8D, the eartip 804 may include a ring 832 that engages the nozzle 108 to prevent rotation. In this regard, the ring 832 conforms to the elongated shape of the nozzle 108, thereby preventing improper attachment of the eartip 804 when it is attached to the nozzle 108. As with the various embodiments described above, the ring 832 may be formed from a hard plastic, such as glass-filled polyimide.

[0069] 8C and 8D , the ring 832 defines a recess 834 (e.g., annular groove) that extends around the inner surface of the inner wall 826 and is configured to receive an O-ring 835 (e.g., a rubber O-ring) that seats in a corresponding recess 136 (e.g., annular groove) formed in and extending around the outer surface of the nozzle 108. In this implementation, engagement of the retention features 834, 136 with the O-ring 835 helps to retain the eartip 804 on the nozzle 108 and also provides a good acoustic seal between the earbud 102 and the eartip 804.

[0070] 8C and 8D, the ring 832 can also define a lip 837 that overlaps the end of the nozzle 108. The lip 837 can support a wax guard 838 (e.g., a screen that can be heat staked to the lip 837), which can be an alternative to or in addition to a wax guard 840 (FIG. 8D) on the nozzle 108 itself.

[0071] 9A-9D show another implementation of an eartip 904 that includes a body 920 configured to attach to an earbud (e.g., earbud 102 of FIGS. 1A and 1B). The body 920 includes a first end 922 and a second end 924 opposite the first end 922. The body 920 further includes an inner wall 926 extending between the first end 922 and the second end 924. The inner wall 926 defines and encloses a hollow passage 928 that can be configured to conduct sound waves. The inner wall 926 has an elongated cross-sectional shape, such as an ellipse, an oval, a racetrack shape (with parallel sides and rounded ends extending between the parallel sides, also known as a "stadium"), or an elongated shape with rounded ends and curved splines connecting them, as shown in FIG. 9B. Here, a "cross-section" or "cross-sectional" should be understood to be perpendicular to the central axis of the inner wall 926. The body 902 also includes an outer wall 930 connected to the inner wall 926 at a first end 922. The outer wall 930 extends away from the inner wall 926 toward a second end 924. In the illustrated example, the outer wall 930 is dome-shaped; however, other shapes, such as a cone, are also contemplated. As shown in FIG. 9C , the outer wall 930 extends beyond the second end 924. In alternative implementations, the outer wall 930 may extend toward, but not necessarily reach, the second end 924.

[0072] The embodiment shown in Figures 9A-9D again utilizes a viscoelastic material with frequency reinforcement behavior, such as a styrenic TPE with viscoelastic properties, e.g., A9 TPE, which may include any of the surface treatments or compounds described above with respect to Figures 7A-7D.

[0073] As shown in FIGS. 9B-9D , the eartip 904 can include a ring 932 that engages with the nozzle 108 to prevent rotation. In this regard, the ring 932 conforms to the elongated shape of the nozzle 108, thereby preventing improper attachment of the eartip 904 when the eartip 904 is attached to the nozzle 108. As with the various embodiments described above, the ring 932 can be formed of a hard plastic, such as glass-filled polyimide. The ring 932 also defines one or more retention features 934, e.g., one or more protrusions, extending outward from the inner surface of the inner wall 926 and configured to engage complementary retention features 136, e.g., recesses, defined by the outer surface of the nozzle 108. The engagement of the retention features 934, 136 helps to retain the eartip 904 on the nozzle 108.

[0074] The viscoelastic material defines a tapered portion 935 of the inner wall 926 that narrows the hollow passageway 928 and tapers inward to provide an interference fit with the end of the nozzle 108. The interference 936 between the tapered portion 935 of the inner wall 926 and the nozzle 108 provides a good acoustic seal between the earbud 102 and the eartip 904.

[0075] 10A-10F show yet another implementation of an eartip 1004 configured to fit at least partially within a person's ear canal. The eartip 1004 includes a body 1020 configured to be mounted on an earbud 102. The body 1020 includes a first end 1022 and a second end 1024 opposite the first end 1022. The body 1020 further includes an inner wall 1026 extending between the first end 1022 and the second end 1024. The inner wall 1026 defines and surrounds a hollow passage 1028 that can be configured to conduct sound waves. The inner wall 1026 has an elongated cross-sectional shape, such as an oval, an ellipse, a racetrack shape (with parallel sides and rounded ends extending between them, also known as a "stadium"), or an elongated shape with rounded ends and curved splines connecting them, as shown in FIG. 10B. Here, "cross-section" or "cross-sectional" should be understood to be perpendicular to the central axis of the inner wall 1026. The body 1020 also includes an outer wall 1030 connected to the inner wall 1026 at the first end 1022. The outer wall 1030 extends away from the inner wall 1026 toward the second end 1024. In the illustrated example, the outer wall 1030 is dome-shaped; however, other shapes, such as a cone, are also contemplated. As shown in FIG. 10C, the outer wall 1030 extends beyond the second end 1024. In alternative implementations, the outer wall 1030 may extend toward the second end 1024 but not necessarily all the way to the second end 1024 .

[0076] The embodiment shown in Figures 10A-10E uses two different materials of different hardness to form the eartip 1004, which is formed in a two-shot molding process. A first material, a high durometer compliant material such as a high durometer silicone, e.g., 60 Shore A to 80 Shore A silicone, e.g., 70 Shore A silicone, is used to form the inner wall 1026. The first material also defines a retention feature 1034, e.g., a protrusion, extending around the inner surface of the inner wall 1026 and configured to engage with a complementary retention feature 1036, e.g., a recess, defined by and extending around the outer surface of the nozzle 1008. The engagement of the retention features 1034, 1036 helps to retain the eartip 1004 on the nozzle 108 and provides a good acoustic seal between the earbud 1002 and the eartip 1004.

[0077] The retention feature 1034 has two flat ends 1035 and two curved splines 1037 connecting them. The thickness t1 of the splines 1037 (FIG. 10C) is greater than the thickness t2 of the ends 1035 (FIG. 10E). As shown in FIG. 11, the recess 1036 on the nozzle 108 similarly comprises two flat ends 1039 and two splines 1041 connecting them. The width w1 of the recess 1036 along the splines 1037 (FIG. 10D) is greater than the width w2 along the flat ends 1039 (FIG. 10F) to accommodate the additional thickness of the splines 1041 of the protrusion 1034. Similarly, the width w2 of the recess 1036 along the flat ends 1035 is sized to accommodate the flat ends 1039 of the protrusion 1034. Thus, the respective shapes of the protrusion 1034 and recess 1036 are secured to one another to prevent improper installation of the eartip 1004 on the nozzle 108 and to prevent rotation of the eartip 1004 relative to the nozzle 108. The nozzle 108 in FIG. 11 is shown with an integrated wax guard 1040.

[0078] The outer wall 1030 is molded around a high durometer material. For comfort, the outer wall 1030 is formed of a low durometer material, such as low durometer silicone, for example, 10 Shore A to 30 Shore A silicone, e.g., 20 Shore A silicone. The outer wall 1030 is the portion of the eartip 1004 that contacts and conforms to the user's ear canal, forming an acoustic seal therebetween. In particular, as shown in FIG. 10A , the outer wall 1030 is in the shape of a dome having an elongated cross-sectional shape, for example, an ellipse, an oval, or a racetrack shape (with parallel sides and rounded ends extending between the parallel sides, also known as a "stadium"). Here, "cross-section" or "cross-sectional" should be understood to be perpendicular to the central axis of the dome / outer wall 1030.

[0079] The eartip 1004 may be formed in a two-shot molding process in which the inner wall 1026 is formed in a first molding step, followed by the outer wall 130 in a second molding step.

[0080] While various examples have been described and illustrated herein, those skilled in the art will readily conceive of numerous other means and / or structures for performing the functions and / or results and / or obtaining one or more of the advantages described herein, and each of such modifications and / or variations is deemed to be within the scope of the examples described herein. More generally, those skilled in the art will readily recognize that all parameters, dimensions, materials, and configurations described herein are exemplary, and that the actual parameters, dimensions, materials, and / or configurations will depend on the particular application or applications for which the teachings of the present invention are used. Those skilled in the art will recognize or be able to ascertain, using no more than routine experimentation, many equivalents to the specific examples described herein. Accordingly, it is to be understood that the foregoing examples are presented by way of example only and that, within the scope of the appended claims and equivalents thereof, the examples may be practiced otherwise than as specifically described and claimed. Examples of the present disclosure are directed to each individual feature, system, article, material, kit, and / or method described herein. Furthermore, any combination of two or more such features, systems, articles, materials, kits, and / or methods is included within the inventive scope of the present disclosure, if such features, systems, articles, materials, kits, and / or methods are not mutually inconsistent.

Claims

1. An eartip, A body configured to be attached to an earbud, the body comprising: a first end; a second end opposite the first end; and an inner wall extending between the first end and the second end, the inner wall defining and enclosing a hollow passage configured to conduct acoustic waves; an outer wall connected to the inner wall at the first end and extending away from the inner wall toward the second end; the inner wall is configured to engage a nozzle on the earbud; The eartip, wherein the inner wall includes a retention feature configured to engage with the nozzle, and the outer wall and the retention feature are at least partially formed from a viscoelastic material including a styrene-based TPE having viscoelastic properties.

2. The eartip of claim 1 , wherein an outer surface of the outer wall is treated with a surface treatment selected from electron beam treatment and photoionization to improve sebum resistance.

3. The eartip of claim 1 , wherein the outer surface of the outer wall has a soft-touch coating.

4. The eartip of claim 3 , wherein the soft touch coating comprises a 50% SIBS / 50% silicone (wt / wt) soft touch coating.

5. 10. The eartip of claim 1, wherein the viscoelastic material comprises a composition including the styrene-based TPE having viscoelastic properties and one or more phase change materials capable of changing phase from a solid state to a liquid state at a predetermined phase change temperature.

6. The eartip of claim 5, wherein the predetermined phase change temperature is between 25°C and 35°C.

7. The eartip of claim 5, wherein the composition has a hardness of 5 Shore A to 50 Shore A, and the amount of the phase change material in the composition is 10% to 40% by weight.

8. The eartip of claim 1 , wherein the retention feature is configured to engage a mating retention feature on the nozzle.

9. The eartip of claim 1 , wherein the inner wall is formed of a hard plastic and further includes a ring configured to engage the nozzle.

10. 10. The eartip of claim 9, wherein the ring defines a recess extending around an inner surface of the inner wall and is configured to receive an O-ring seated in a corresponding recess formed in and extending around an outer surface of the nozzle.

11. The eartip of claim 1 , wherein the styrenic TPE having viscoelastic properties is A9 TPE.

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