Hearing protection device

Abstract

A hearing protection device (200) is provided that includes a headband and a pair of earmuffs coupled to opposing ends of the headband. Each earmuff from the pair of earmuffs includes a cushion (122) and an ear cup (130) including a support plate (140). The cushion (122) is coupled to the support plate (140). Each earmuff further includes a seal component (150) that seals the cushion (122) to the support plate (140) and the ear cup (130). The seal component (150) includes an elastic material.

Description

[0001] HEARING PROTECTION DEVICE

[0002] Technical Field

[0003] The present disclosure generally relates to a hearing protection device, an earmuff for a hearing protection device, and a cushion component for an earmuff.

[0004] Background

[0005] Earmuff-style hearing protection devices are widely used in industry for protecting users against environmental noise. Typically, such devices include a pair of earmuffs fastened to a headband, a helmet, or other headpiece. Each earmuff typically includes a rigid ear cup, and a cushion to seal the ear cup against a side of a wearer's head around the ear and to improve comfort. Generally, the cushion is coupled to the ear cup via an interface.

[0006] Summary

[0007] In a first aspect, the present disclosure provides a hearing protection device. The hearing protection device includes a headband and a pair of earmuffs coupled to opposing ends of the headband. Each earmuff from the pair of earmuffs includes a cushion and an ear cup including a support plate. The cushion is coupled to the support plate. Each earmuff further includes a seal component that seals the cushion to the support plate and the ear cup. The seal component includes an elastic material.

[0008] In a second aspect, the present disclosure provides an earmuff for a hearing protection device. The earmuff includes an ear cup including a hollow space. The earmuff further includes a cushion and a support plate configured to couple the cushion to the ear cup. The earmuff further includes a seal component configured to seal the cushion to the support plate and the ear cup. The seal component includes an elastic material.

[0009] In a third aspect, the present disclosure provides a cushion component for an earmuff. The cushion component includes a cushion including a resilient and deformable material. The cushion includes a first coupling portion. The cushion component further includes a support plate coupled to the cushion. The support plate is made of a hard material. The cushion component further includes a seal component configured to seal the cushion to the support plate and an ear cup. The seal component includes a second coupling portion configured to couple to the first coupling portion. The cushion component further includes a coupling mechanism configured to couple the cushion to the ear cup. The seal component deforms when the cushion is coupled to the ear cup.

[0010] In a fourth aspect, the present disclosure provides a cushion component for an earmuff. The cushion component includes a cushion including a resilient and deformable material. The cushion component further includes a support plate coupled to the cushion. The support plate is made of a hard material. The cushion component further includes a seal component configured to seal the cushion to the support plate and an ear cup. The seal component includes an elastic material. The cushion component further includes a coupling mechanism configured to couple the cushion to the ear cup. The seal component deforms when the cushion is coupled to the ear cup.

[0011] The details of one or more examples of the disclosure are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the disclosure will be apparent from the description and drawings, and from the claims.

[0012] Brief Description of Drawings

[0013] Exemplary embodiments disclosed herein may be more completely understood in consideration of the following detailed description in connection with the following figures. The figures are not necessarily drawn to scale. Like numbers used in the figures refer to like components. However, it will be understood that the use of a number to refer to a component in a given figure is not intended to limit the component in another figure labeled with the same number.

[0014] FIG. 1 is a schematic perspective view of a hearing protection device, in accordance with embodiments herein.

[0015] FIGS. 2-9 illustrate schematic partial sectional views illustrating various configurations of hearing protection devices taken along a section plane similar to a section plane A shown in FIG. 1, in accordance with embodiments herein.

[0016] FIG. 10 is a graph illustrating standard deviation of attenuation with respect to frequency for an existing reference cushion and an exemplary cushion component of the present disclosure.

[0017] Detailed Description

[0018] In the following description, reference is made to the accompanying figures that form a part thereof and in which various embodiments are shown by way of illustration. It is to be understood that other embodiments are contemplated and may be made without departing from the scope or spirit of the present disclosure. The following detailed description, therefore, is not to be taken in a limiting sense.

[0019] In the following disclosure, the following definitions are adopted.

[0020] As used herein, the term “earmuff’ generally refers to a component that is dimensioned to encircle and fully enclose an ear of a wearer and is constructed to provide sound attenuation. As used herein, the term “headband” generally refers to a device that is constructed to retain an earmuff and compress the earmuff against a head of a wearer.

[0021] As used herein, the term “hearing protective device” generally refers to a personal protective equipment (PPE) article worn to reduce harmful auditory or annoying subjective effects of sound. As used herein, the term “hearing protection device” may refer either to passive hearing protection or active hearing protection devices.

[0022] As used herein, the term “hard material” means and includes any material having a young’s modulus or flexural modulus greater than 0.8 gigapascal (GPa).

[0023] As used herein, the term “soft material” means and includes any material having a Shore durometer hardness between 1 Shore A and 60 Shore D.

[0024] As used herein, all numbers should be considered modified by the term “about”. As used herein, “a,” “an,” “the,” “at least one,” and “one or more” are used interchangeably.

[0025] As used herein as a modifier to a property or attribute, the term “generally”, unless otherwise specifically defined, means that the property or attribute would be readily recognizable by a person of ordinary skill but without requiring absolute precision or a perfect match (e.g., within + / - 20 % for quantifiable properties).

[0026] The term “substantially”, unless otherwise specifically defined, means to a high degree of approximation (e.g., within + / - 10% for quantifiable properties) but again without requiring absolute precision or a perfect match.

[0027] The term “about”, unless otherwise specifically defined, means to a high degree of approximation (e.g., within + / - 5% for quantifiable properties) but again without requiring absolute precision or a perfect match.

[0028] As used herein, the terms “first” and “second” are used as identifiers. Therefore, such terms should not be construed as limiting of this disclosure. The terms “first” and “second” when used in conjunction with a feature or an element can be interchanged throughout the embodiments of this disclosure.

[0029] As used herein, “at least one of A and B” should be understood to mean “only A, only B, or both A and B”.

[0030] As used herein, the recitations of numerical ranges by endpoints include all numbers subsumed within that range as well as the endpoints (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, 5, etc.).

[0031] Earmuff-style hearing protective devices typically include a pair of earmuffs fastened to a headband, a helmet, or other headpiece. Each earmuff typically includes a rigid ear cup and a cushion to seal the ear cup against a side of a wearer's head around the ear. Generally, an interface between the cushion and the ear cup includes different types of snap solutions. The snap solutions mostly include a rigid component (or a support plate) in order to create a mechanically robust attachment. The rigidity of the support plate causes a design of the earmuff to be sensitive to variations which may lead to acoustic leaks and may potentially be dangerous for the wearer since the hearing protective device may not produce the desired attenuation. Moreover, in the current designs, the support plate has a dominant resonance frequency which is positioned within a frequency range where the attenuation is desired. This may decrease an attenuation performance of the hearing protection device.

[0032] The present disclosure provides a hearing protection device. The hearing protection device includes a headband and a pair of earmuffs coupled to opposing ends of the headband. Each earmuff from the pair of earmuffs includes a cushion and an ear cup including a support plate. The cushion is coupled to the support plate. Each earmuff further includes a seal component that seals the cushion to the support plate and the ear cup. The seal component includes an elastic material.

[0033] The hearing protection device of the present disclosure includes the seal component that seals the cushion to the support plate and the ear cup. The seal component includes the elastic material. The seal component provides adaptability for different design tolerances and variations due to temperature fluctuations. In some embodiments, the support plate may be made entirely from an elastic material, thereby enhancing attenuation properties of the hearing protection device by avoiding certain resonance frequencies. Thus, a stiffness and an internal damping of the support plate may be controlled via material selection. In some other embodiments, the support plate may be made majorly from the elastic material, with a low stiffness and a high internal dampening, in most of the component, and from a rigid material which may provide stiffness only where it is required. Alternatively, the support plate may be made entirely from the rigid material. In such cases, the seal component may provide adaptability for different design tolerances and improved attenuation performance.

[0034] Referring now to the Figures, FIG. 1 is a schematic perspective view of a hearing protection device 100. In some embodiments, the hearing protection device 100 may be used to protect a wearer (not shown) against environmental noise. In some embodiments, the hearing protection device 100 may be a part of a personal protective equipment (PPE).

[0035] Examples of PPE may include, but are not limited to, respiratory protection equipment (including disposable respirators, reusable respirators, powered air purifying respirators, self- contained breathing apparatus, and supplied air respirators), facemasks, oxygen tanks, air bottles, protective eyewear, such as visors, goggles, fdters or shields (any of which may include augmented reality functionality), protective headwear, such as hard hats, hoods, or helmets, hearing protection (including ear plugs and earmuffs), protective shoes, protective gloves, other protective clothing, such as coveralls, aprons, coat, vest, suits, boots, and / or gloves, protective articles, such as sensors, safety tools, detectors, global positioning devices, mining cap lamps, fall protection harnesses, exoskeletons, self-retracting lifelines, heating and cooling systems, gas detectors, and any other suitable gear configured to protect the wearer from injury. The PPE may also include any other type of clothing or device / equipmentthat may be worn or used by the wearer to protect against fire, extreme temperatures, reduced oxygen levels, explosions, reduced atmospheric pressure, radiation, and / or biologically harmful materials.

[0036] The hearing protection device 100 includes a headband 102 and a pair of earmuffs 106a, 106b (collectively, earmuffs 106) coupled to opposing ends 104a, 104b of the headband 102. Specifically, the earmuff 106a is coupled to the end 104a of the headband 102 and the earmuff 106b is coupled to the end 104b of the headband 102. The pair of earmuffs 106a, 106b are similar in construction and geometry. Each opposing end 104a, 104b of the headband 102 terminates in a respective pair of attachment clips 108a, 108b. Only one attachment clip 108a, 108b from the pair of attachment clips 108a, 108b is visible in FIG. 1. The earmuff 106a is pivotally coupled to the headband 102 via the pair of attachment clips 108a and the earmuff 106b is pivotally coupled to the headband 102 via the pair of attachment clips 108b.

[0037] In some embodiments, the headband 102 may be made from a suitably flexible but relatively stiff material, such that each earmuff 106a, 106b may be positioned in a defined position upon a respective ear of the wearer during use. It should be understood that, in alternative embodiments, the headband 102 may be replaced with a helmet, or other headpiece.

[0038] Each earmuff 106a, 106b includes a cushion component 120 including a cushion 122 and an ear cup 130 including a support plate 140 (shown in FIGS. 2-7). Cushion 122, in accordance with embodiments herein, provides a comfortable fit and a sound-attenuating seal against the ears of the wearer when the hearing protection device 100 is worn by the wearer. In some embodiments, the cushion 122 includes a resilient and deformable material. The ear cup 130 has a cup-shaped distal exterior surface with a generally arcuate convex shape, a rim (not visible), and a concave interior surface (not visible) proximate the wearer's ear.

[0039] In some embodiments, the ear cup 130 may be made from a variety of materials that may be familiar to persons having ordinary skill in the art, such as styrene (e.g., acrylonitrile butadiene styrene or ABS), various polyolefins, polycarbonates, or other impact resistant plastics. In some embodiments, the ear cup 130 includes a hollow space (not visible). Alternatively, in some embodiments, the ear cup 130 may include a sound-attenuating material, such as a foam, in order to optimize sound-damping properties of the hearing protection device 100. These, and other configurations, are illustrated in FIGS. 2-9. However, while some example configurations are illustrated herein, it is expressly contemplated that other suitable configurations are possible and envisioned herein.

[0040] As shown in FIG. 1, the cushion 122 may be generally formed as an oval cushion and may include a solid foam, e.g., a polyurethane based foam. However, in some embodiments, the cushion 122 may be foam-less, i.e., a shell without a material fdling. The foam-less cushion 122 may have air within the shell. In such cases, the cushion 122 may be in the form of an elastomeric shell. In some embodiments, the cushion 122 may be made of a material, such as a thermoplastic elastomer (TPE), e.g., thermoplastic styrene (TPS), thermoplastic polyurethanes (TPU), thermoplastic vulcanizates (TPV), thermoplastic polyamide (TPA), thermoplastic polyolefins (TPO), etc., a natural rubber, synthetic rubbers, such as nitrile butadiene rubber (NBR), ethylene propylene diene monomer (EPDM), ethylene propylene rubber (EPR), fluorinated rubber (FKM), neoprene, silicone rubbers, and / or the like. In some embodiments, the cushion 122 may have a composite construction with a generally impervious outer cover and a resilient interior and may be made from a variety of materials.

[0041] Although FIG. 1 shows the cushion 122 that is oval-shaped, it should be noted that the cushion 122 may alternatively be designed in other suitable geometrical shapes, e.g., circular, rectangular, polygonal, or virtually any form which defines an aperture allowing the cushion 122 to be positioned around the ear of the wearer. Also, the ear cup 130 may be designed as any type of shell, cup, bowl, or container configured for supporting the cushion 122 and for allowing the headband 102 to be attached.

[0042] Each earmuff 106a, 106b further includes a seal component 150 that seals the cushion 122 to the support plate 140 (shown in FIGS. 2-9) and the ear cup 130. The seal component 150 includes an elastic material. The elastic material may be a soft material. Examples of the soft elastic material may include, but are not limited to, thermoplastic elastomers (TPE), such as thermoplastic styrene (TPS), thermoplastic polyurethanes (TPU), thermoplastic vulcanizates (TPV), thermoplastic polyamide (TPA), thermoplastic polyolefins (TPO), etc., natural rubbers, synthetic rubbers, such as nitrile butadiene rubber (NBR), ethylene propylene diene monomer (EPDM), ethylene propylene rubber (EPR), fluorinated rubber (FKM), neoprene, silicone rubbers, and / or the like.

[0043] FIG. 2 is a schematic partial sectional view of a hearing protection device 200 in accordance with embodiments herein. The sectional view is taken along a section plane similar to a section plane A shown in FIG. 1. In some embodiments, the hearing protection device 200 may be similar and functionally equivalent to the hearing protection device 100 shown in FIG. 1, and same components in this embodiment are referred to by same reference numerals and differences between the embodiments are discussed. As shown in FIG. 2, the cushion 122 of the cushion component 120 is coupled to the support plate 140 and the seal component 150 seals the cushion 122 to the support plate 140 and the ear cup 130. In some embodiments, the cushion 122 includes a foam.

[0044] In the illustrated embodiment of FIG. 2, the seal component 150 includes a portion of the support plate 140. Specifically, the seal component 150 is integrated into the support plate 140. In other words, the support plate 140 includes the seal component 150. Further, the support plate 140 includes the elastic material (i.e., the soft material) of the seal component 150. Thus, the seal component 150 and the support plate 140 are made of the same material. In other words, the support plate 140 is flexible.

[0045] In accordance with embodiments herein, the cushion 122 is removable from the ear cup 130. Specifically, the cushion 122 may be a fully replaceable cushion.

[0046] In some embodiments, the support plate 140 includes a top surface 142 defining a support plate axis SA along a length L of the support plate 140. The seal component 150 includes an upper portion 152 disposed above the support plate axis SA and a lower portion 154 disposed below the support plate axis SA. In some embodiments, the cushion 122 is at least partially received between the upper portion 152 and the lower portion 154 of the seal component 150. In some embodiments, the cushion 122 includes a groove 124. The groove 124 at least partially receives the seal component 150 therein. Specifically, the groove 124 at least partially receives the upper portion 152 of the seal component 150.

[0047] In some embodiments, the support plate 140 directly contacts the ear cup 130. Further, the seal component 150 directly contacts the ear cup 130. In some embodiments, the cushion 122 is coupled to the support plate 140 via a mechanical coupling. In some embodiments, the mechanical coupling includes a snap. Specifically, the upper portion 152 and the lower portion 154 of the seal component 150 receives a portion of the cushion 122 in a snap-fit manner, thereby achieving a soft adaptable sealing between the cushion 122 and the ear cup 130. For example, the cushion 122 may include a locking bead which is received between the upper portion 152 and the lower portion 154 of the seal component 150. In some embodiments, the seal component 150 deforms when the cushion 122 is sealed to the support plate 140 and the ear cup 130.

[0048] FIG. 3 is a schematic partial sectional view of a hearing protection device 300 in accordance with embodiments herein. The sectional view is taken along a section plane similar to the section plane A shown in FIG. 1 . The hearing protection device 300 is similar and functionally equivalent to the hearing protection device 100 shown in FIG. 1, and same components in this embodiment are referred to by same reference numerals and differences between the embodiments are discussed.

[0049] In the illustrated embodiment of FIG. 3, the cushion 122 is permanently coupled to the support plate 140. In some embodiments, the cushion 122 is coupled to the support plate 140 by an adhesive or welding. However, it should be understood that the cushion 122 may be permanently coupled to the support plate 140 by any other suitable mechanism based on application requirements. Furthermore, the cushion 122 may be permanently coupled to the seal component 150. In some embodiments, the cushion 122 includes a foam. Further, in the embodiment illustrated in FIG. 3, the seal component 150 seals the cushion 122 to the support plate 140 and the ear cup 130. In the illustrated embodiment, the support plate 140 includes the seal component 150. Specifically, the seal component 150 is integrated into the support plate 140. Further, the support plate 140 includes the elastic material (i.e., the soft material) of the seal component 150. Thus, the seal component 150 and the support plate 140 are made of the same material. In other words, the support plate 140 is flexible.

[0050] In some embodiments, the support plate 140 directly contacts the ear cup 130. Further, the seal component 150 directly contacts the ear cup 130. In some embodiments, the seal component 150 deforms when the cushion 122 is sealed to the support plate 140 and the ear cup 130, thereby achieving a soft adaptable sealing between the cushion 122 and the ear cup 130.

[0051] FIG. 4 is a schematic partial sectional view of a hearing protection device 400 in accordance with embodiments herein. The sectional view is taken along a section plane similar to the section plane A shown in FIG. 1 . The hearing protection device 400 is similar and functionally equivalent to the hearing protection device 100 shown in FIG. 1, and same components in this embodiment are referred to by same reference numerals and differences between the embodiments are discussed.

[0052] In the illustrated embodiment of FIG. 4, the support plate 140 is made of a hard material. Examples of the hard material may include, but are not limited to, acrylonitrile butadiene styrene (ABS), polypropylene (PP), polyvinyl chloride (PVC), polyurethane (PU), acrylonitrile styrene acrylate (ASA), polycarbonate (PC), polyethylene (PE), polyethylene terephthalate (PET or PETE), and / or the like. In other words, the support plate 140 is inelastic.

[0053] In some embodiments, the seal component 150 is coupled to the support plate 140. Specifically, the seal component 150 is co-molded with the support plate 140. For example, the seal component 150 is coupled to the support plate 140 via multi-material injection molding. In some embodiments, the seal component 150 is coupled to the support plate 140 via mechanical coupling mechanisms, e.g., adhesives, etc. The cushion 122 is coupled to the support plate 140 and the seal component 150 seals the cushion 122 to the support plate 140 and the ear cup 130. In accordance with embodiments herein, the cushion 122 is removable from the ear cup 130. Specifically, the cushion 122 is a replaceable cushion. In some embodiments, the cushion 122 includes a foam.

[0054] In some embodiments, the support plate 140 includes the top surface 142 defining the support plate axis SA along the length L of the support plate 140. The seal component 150 includes the upper portion 152 disposed above the support plate axis SA and the lower portion 154 disposed below the support plate axis SA. In some embodiments, the cushion 122 is at least partially received between the upper portion 152 and the lower portion 154 of the seal component 150.

[0055] In some embodiments, the cushion 122 is coupled to the support plate 140 via a mechanical coupling. In some embodiments, the mechanical coupling includes a snap. Specifically, the upper portion 152 and the lower portion 154 of the seal component 150 receives a portion of the cushion 122 in a snap-fit manner, thereby achieving a soft adaptable sealing between the cushion 122 and the ear cup 130.

[0056] In some embodiments, the cushion 122 includes a first coupling portion 126. In some embodiments, the seal component 150 includes a second coupling portion 156 configured to couple to the first coupling portion 126 of the cushion 122. In some embodiments, the first coupling portion 126 of the cushion 122 or the second coupling portion 156 of the seal component 150 includes the groove 124. In some embodiments, the first coupling portion 126 of the cushion 122 or the second coupling portion 156 of the seal component 150 includes a protrusion 162.

[0057] In the illustrated embodiment of FIG. 4, the cushion 122 (or the first coupling portion 126) includes the groove 124 and the seal component 150 (or the second coupling portion 156) includes the protrusion 162. The groove 124 of the cushion 122 (or the first coupling portion 126) at least partially receives the seal component 150 therein. Specifically, the protrusion 162 of the seal component 150 is configured to couple to the groove 124 of the cushion 122. Further, the groove 124 at least partially receives the upper portion 152 (or the second coupling portion 156 or the protrusion 162) of the seal component 150.

[0058] In some embodiments, the support plate 140 directly contacts the ear cup 130. Further, the seal component 150 directly contacts the ear cup 130. In some embodiments, the seal component 150 deforms when the cushion 122 is sealed to the support plate 140 and the ear cup 130. In some embodiments, the cushion 122 is indirectly sealed to the support plate 140, such that the seal component 150 couples to the cushion 122 on a first side 157 of the seal component 150, and to the support plate 140 on a second side 158 of the seal component 150. In some embodiments, the second side 158 is opposite the first side 157. In some embodiments, the seal component 150 includes a seal aperture 164 configured to couple to a support plate protrusion 144 of the support plate 140. Alternatively, the seal component 150 may include a seal protrusion (not shown) configured to couple to a support plate aperture (not shown) of the support plate 140.

[0059] In some embodiments, the cushion component 120 further includes a coupling mechanism 128 configured to couple the cushion 122 to the ear cup 130. The coupling mechanism 128 may allow the cushion 122 to be coupled to the ear cup 130. Specifically, the seal component 150 is configured to contact the ear cup 130 when the cushion component 120 is coupled to the ear cup 130. Further, the seal component 150 deforms when the cushion 122 is coupled to the ear cup 130. Specifically, the coupling mechanism 128 may involve deformation of the seal component 150 for coupling the cushion 122 to the ear cup 130. FIG. 5 is a schematic partial sectional view of a hearing protection device 500 in accordance with embodiments herein. The sectional view is taken along a section plane similar to the section plane A shown in FIG. 1 . The hearing protection device 500 is similar and functionally equivalent to the hearing protection device 100 shown in FIG. 1, and same components in this embodiment are referred to by same reference numerals and differences between the embodiments are discussed.

[0060] In the illustrated embodiment of FIG. 5, the cushion 122 is permanently coupled to the support plate 140. For example, the cushion 122 may be coupled to the support plate 140 by an adhesive, welding, or other suitable technique. It is expressly contemplated that the cushion 122 may be permanently coupled to the support plate 140 by any other suitable mechanism based on application requirements. Furthermore, the cushion 122 is permanently coupled to the seal component 150. In some embodiments, the cushion 122 includes a foam.

[0061] Further, the support plate 140 is made of a hard material. Examples of the hard material may include, but are not limited to, acrylonitrile butadiene styrene (ABS), polypropylene (PP), polyvinyl chloride (PVC), polyurethane (PU), acrylonitrile styrene acrylate (ASA), polycarbonate (PC), polyethylene (PE), polyethylene terephthalate (PET or PETE), and / or the like. In other words, the support plate 140 is inelastic.

[0062] In some embodiments, the seal component 150 is coupled to the support plate 140. Specifically, the seal component 150 is co-molded with the support plate 140. For example, the seal component 150 is coupled to the support plate 140 via muti -material injection molding. In some embodiments, the seal component 150 is coupled to the support plate 140 via mechanical coupling mechanisms, e.g., adhesives, etc. The cushion 122 is coupled to the support plate 140 and the seal component 150 seals the cushion 122 to the support plate 140 and the ear cup 130.

[0063] In some embodiments, the support plate 140 includes the top surface 142 defining the support plate axis SA along the length L of the support plate 140. The seal component 150 includes the upper portion 152 disposed above the support plate axis SA and the lower portion 154 disposed below the support plate axis SA. In some embodiments, the support plate 140 is at least partially received between the upper portion 152 and the lower portion 154 of the seal component 150.

[0064] In some embodiments, the support plate 140 directly contacts the ear cup 130. Further, the seal component 150 directly contacts the ear cup 130. In some embodiments, the cushion 122 is indirectly sealed to the support plate 140 and the ear cup 130, such that the seal component 150 couples to the cushion 122 on the first side 157 of the seal component 150, and to the support plate 140 on the second side 158 of the seal component 150. In some embodiments, the second side 158 is opposite the first side 157. In some embodiments, the seal component 150 includes the seal aperture 164 configured to couple to the support plate protrusion 144 of the support plate 140. Alternatively, the seal component 150 may include a seal protrusion (not shown) configured to couple to a support plate aperture (not shown) of the support plate 140.

[0065] In some embodiments, the cushion component 120 further includes the coupling mechanism 128 configured to couple the cushion 122 to the ear cup 130. The seal component 150 is configured to contact the ear cup 130 when the cushion component 120 is coupled to the ear cup 130. Specifically, in some embodiments herein, the seal component 150 deforms when the cushion 122 is coupled to the ear cup 130, thereby achieving a soft adaptable sealing between the cushion 122 and the ear cup 130.

[0066] FIG. 6 is a schematic partial sectional view of a hearing protection device 600 in accordance with embodiments herein. The sectional view is taken along a section plane similar to the section plane A shown in FIG. 1 . The hearing protection device 600 is similar and functionally equivalent to the hearing protection device 100 shown in FIG. 1, and same components in this embodiment are referred to by same reference numerals and differences between the embodiments are discussed.

[0067] In the illustrated embodiment of FIG. 6, the support plate 140 is made of a hard material. Examples of the hard material may include, but are not limited to, acrylonitrile butadiene styrene (ABS), polypropylene (PP), polyvinyl chloride (PVC), polyurethane (PU), acrylonitrile styrene acrylate (ASA), polycarbonate (PC), polyethylene (PE), polyethylene terephthalate (PET or PETE), and / or the like. In other words, the support plate 140 is inelastic.

[0068] Further, in some embodiments herein, the cushion 122 includes a solid foam material. The cushion 122 further includes the seal component 150. Specifically, the seal component 150 is integrated into the cushion 122. In some embodiments, the cushion 122 is permanently coupled to the support plate 140. Specifically, the cushion 122 is coupled to the support plate 140 by an adhesive, molding, or welding. In other words, the cushion 122 is glued, molded, or welded to the support plate 140.

[0069] In some embodiments, the support plate 140 includes the top surface 142 defining the support plate axis SA along the length L of the support plate 140. The seal component 150 includes the upper portion 152 disposed above the support plate axis SA and the lower portion 154 disposed below the support plate axis SA. In some embodiments, the support plate 140 is at least partially received between the upper portion 152 and the lower portion 154 of the seal component 150.

[0070] In some embodiments, the support plate 140 directly contacts the ear cup 130. Further, the seal component 150 directly contacts the ear cup 130. Furthermore, the cushion 122 directly contacts the ear cup 130 (via the seal component 150). In some embodiments, the seal component 150 includes the seal aperture 164 configured to couple to the support plate protrusion 144 of the support plate 140. Alternatively, the seal component 150 may include a seal protrusion (not shown) configured to couple to a support plate aperture (not shown) of the support plate 140. In some embodiments, the cushion component 120 further includes the coupling mechanism 128 configured to couple the cushion 122 to the ear cup 130. The seal component 150 is configured to contact the ear cup 130 when the cushion component 120 is coupled to the ear cup 130. Specifically, in some embodiments herein, the seal component 150 may deform when the cushion 122 is coupled to the ear cup 130, thereby achieving a soft adaptable sealing between the cushion 122 and the ear cup 130.

[0071] FIG. 7 is a schematic partial sectional view of a hearing protection device 700 in accordance with embodiments herein. The sectional view is taken along a section plane similar to the section plane A shown in FIG. 1 . The hearing protection device 700 is similar and functionally equivalent to the hearing protection device 100 shown in FIG. 1, and same components in this embodiment are referred to by same reference numerals and differences between the embodiments are discussed.

[0072] In the illustrated embodiment of FIG. 7, the support plate 140 is made of a hard material. Examples of the hard material may include, but are not limited to, acrylonitrile butadiene styrene (ABS), polypropylene (PP), polyvinyl chloride (PVC), polyurethane (PU), acrylonitrile styrene acrylate (ASA), polycarbonate (PC), polyethylene (PE), polyethylene terephthalate (PET or PETE), and / or the like. In other words, the support plate 140 is inelastic.

[0073] Further, in some embodiments herein, the cushion 122 includes an elastomeric shell. Specifically, the cushion 122 includes an air-filled elastomeric material. The cushion 122 further includes the seal component 150. Specifically, the seal component 150 is integrated into the cushion 122. In some embodiments, the cushion 122 is coupled to the support plate 140 via a mechanical coupling. For example, the mechanical coupling incudes a snap or adhesive. In other words, the support plate 140 is coupled to the cushion 122 by the snap. In some embodiments, the cushion 122 is permanently coupled to the support plate 140 via the adhesive.

[0074] In some embodiments, the support plate 140 includes the top surface 142 defining the support plate axis SA along the length L of the support plate 140. The seal component 150 includes the upper portion 152 disposed above the support plate axis SA and the lower portion 154 disposed below the support plate axis SA. In some embodiments, the support plate 140 is at least partially received between the upper portion 152 and the lower portion 154 of the seal component 150.

[0075] In some embodiments, the support plate 140 directly contacts the ear cup 130. Further, the seal component 150 directly contacts the ear cup 130. Furthermore, in some embodiments, the cushion 122 directly contacts the ear cup 130 (via the seal component 150). In some embodiments, the seal component 150 includes the seal aperture 164 configured to couple to the support plate protrusion 144 of the support plate 140. Alternatively, the seal component 150 may include a seal protrusion (not shown) configured to couple to a support plate aperture (not shown) of the support plate 140. In some embodiments, the cushion component 120 further includes the coupling mechanism 128 configured to couple the cushion 122 to the ear cup 130. The seal component 150 is configured to contact the ear cup 130 when the cushion component 120 is coupled to the ear cup 130. Specifically, in some embodiments herein, the seal component 150 may deform when the cushion 122 is coupled to the ear cup 130, thereby achieving a soft adaptable sealing between the cushion 122 and the ear cup 130.

[0076] FIG. 8 is a schematic partial sectional view of a hearing protection device 800 in accordance with embodiments herein. The sectional view is taken along a section plane similar to the section plane A shown in FIG. 1 . The hearing protection device 800 is similar and functionally equivalent to the hearing protection device 100 shown in FIG. 1, and same components in this embodiment are referred to by same reference numerals and differences between the embodiments are discussed.

[0077] In the illustrated embodiment of FIG. 8, the support plate 140 is made of a hard material. Examples of the hard material may include, but are not limited to, acrylonitrile butadiene styrene (ABS), polypropylene (PP), polyvinyl chloride (PVC), polyurethane (PU), acrylonitrile styrene acrylate (ASA), polycarbonate (PC), polyethylene (PE), polyethylene terephthalate (PET or PETE), and / or the like. In other words, the support plate 140 is inelastic.

[0078] Further, in some embodiments herein, the cushion 122 includes an elastomeric material. The cushion 122 further includes the seal component 150. Specifically, the seal component 150 is integrated into the cushion 122. In some embodiments, the cushion 122 is permanently coupled to the support plate 140. Specifically, the cushion 122 is co-molded with the support plate 140. For example, the cushion 122 is co-molded with the support plate 140 via multi -material injection molding in a single process.

[0079] In some embodiments, the support plate 140 includes the top surface 142 defining the support plate axis SA along the length L of the support plate 140. The seal component 150 includes the upper portion 152 disposed above the support plate axis SA and the lower portion 154 disposed below the support plate axis SA. In some embodiments, the support plate 140 is at least partially received between the upper portion 152 and the lower portion 154 of the seal component 150.

[0080] In some embodiments, the support plate 140 directly contacts the ear cup 130. Further, the seal component 150 directly contacts the ear cup 130. In some embodiments, the cushion 122 directly contacts the ear cup 130 (via the seal component 150). In some embodiments, the seal component 150 includes the seal aperture 164 configured to couple to the support plate protrusion 144 of the support plate 140. Alternatively, the seal component 150 may include a seal protrusion (not shown) configured to couple to a support plate aperture (not shown) of the support plate 140.

[0081] In some embodiments, the cushion component 120 further includes the coupling mechanism 128 configured to couple the cushion 122 to the ear cup 130. The seal component 150 is configured to contact the ear cup 130 when the cushion component 120 is coupled to the ear cup 130. Specifically, in some embodiments herein, the seal component 150 may deform when the cushion 122 is coupled to the ear cup 130, thereby achieving a soft adaptable sealing between the cushion 122 and the ear cup 130.

[0082] FIG. 9 is a schematic partial sectional view of a hearing protection device 900 in accordance with embodiments herein. The sectional view is taken along a section plane similar to the section plane A shown in FIG. 1 . The hearing protection device 900 is similar and functionally equivalent to the hearing protection device 100 shown in FIG. 1, and same components in this embodiment are referred to by same reference numerals and differences between the embodiments are discussed.

[0083] In the illustrated embodiment of FIG. 9, the support plate 140, the cushion 122, and the seal component 150 are integrally formed as a single piece from an elastic material (i.e., a soft material). In other words, the seal component 150 is integrated into the support plate 140 and the cushion 122. Specifically, the seal component 150 includes a portion of the support plate 140 and the cushion 122. Further, in some embodiments, the seal component 150, the support plate 140, and the cushion 122 are made of the same material. In other words, the support plate 140 and the cushion 122 includes the elastic material of the seal component 150. Thus, in this embodiment, the support plate 140 is flexible.

[0084] In some embodiments, the cushion 122 is permanently coupled to the support plate 140. Specifically, the cushion 122 is co-molded with the support plate 140. For example, the seal component 150 is integrated into the cushion 122 and the seal component 150 via injection molding in a single process. However, it should be understood that the cushion 122 may be permanently coupled to the support plate 140 by any other suitable mechanism based on application requirements. Further, the cushion 122 may be permanently coupled to the seal component 150.

[0085] In some embodiments, the support plate 140 directly contacts the ear cup 130. Further, the seal component 150 directly contacts the ear cup 130. In some embodiments, the cushion 122 directly contacts the ear cup 130 (via the seal component 150). In some embodiments, the cushion component 120 further includes the coupling mechanism 128 configured to couple the cushion 122 to the ear cup 130. The seal component 150 is configured to contact the ear cup 130 when the cushion component 120 is coupled to the ear cup 130. Specifically, in some embodiments herein, the seal component 150 may deform when the cushion 122 is coupled to the ear cup 130, thereby achieving a soft adaptable sealing between the cushion 122 and the ear cup 130.

[0086] Referring now to FIGS. 1-9, the hearing protection device 100 of the present disclosure includes the seal component 150 that seals the cushion 122 to the support plate 140 and the ear cup 130. The seal component 150 includes an elastic material. The seal component 150 provides adaptability for different design tolerances and variations due to temperature fluctuations. In some embodiments, the support plate 140 may be made entirely from an elastic material, thereby enhancing attenuation properties of the hearing protection device 100 by avoiding certain resonance frequencies. Thus, a stiffness and an internal damping of the support plate 140 may be controlled via material selection. In some embodiments, the support plate 140 may be made entirely from a rigid inelastic material. In such cases, the seal component 150 may provide adaptability for different design tolerances and improved attenuation performance.

[0087] The present invention is described herein using a hearing protection device. However, it should be noted that the principles of the invention may alternatively be used in other forms of acoustic devices, such as active hearing protection devices and headphones.

[0088] Examples and Test Data

[0089] The following examples are offered for illustrative purposes only and are not intended to limit the scope of the disclosure in any way. Indeed, various modifications of the disclosure, in addition to those shown and described herein, will become apparent to those skilled in the art from the foregoing description and the following examples and fall within the scope of the appended claims.

[0090] Tests were conducted using a hearing protection device “reference headset” with an existing “reference cushion” and an exemplary cushion component of the present disclosure (including a support plate and a sealing component). The exemplary cushion component (including a cushion), the support plate, and the sealing component were substantially similar to the cushion component 120, the support plate 140, and the sealing component 150, respectively, of the hearing protection device 800 shown in FIG. 8.

[0091] Prototype samples of the exemplary cushion component, the support plate, and the sealing component were made with the following materials and processes. The support plate was made from an inelastic material through three-dimensional printing (3D Printing). The sealing component and the cushion were injection molded. Material used for the sealing component was a thermoplastic elastomer (TPE) with a Shore durometer hardness of 34 shore A. The support plate was used as a part insert for over molding. An acoustic seal was achieved between the sealing component of the cushion and an ear cup (e.g., the ear cup 130 shown in FIG. 8).

[0092] Same reference headset was used for both the existing reference cushion and the exemplary cushion component of the present disclosure. Two different product setups, i.e., the reference headset with the existing reference cushion and the reference headset with the cushion component of the present disclosure were tested for insertion loss in an acoustic test fixture (ATF) to investigate if the elastic soft sealing component of the cushion component of the present disclosure can help to reduce variation in attenuation performance. Insertion loss measurement was conducted according to ISO 4869-3. Each setup was measured at least two times. The cushions of both the setups were removed and turned 180 degrees before they were reattached to the ear cup of the headset for measuring at the second time.

[0093] FIG. 10 is a graph 1000 illustrating attenuation performance of the existing reference cushion and the exemplary cushion component of the present disclosure. Specifically, the graph 1000 illustrates standard deviation of attenuation with respect to frequency for both the existing reference cushion and the exemplary cushion component. A magnitude of the attenuation (in decibels or dB) is shown along the vertical axis or ordinate of the graph 1000. A magnitude of the frequency (in Hertz or Hz) is shown along the horizontal axis or abscissa of the graph 1000. The attenuation / standard deviation was measured according to standard ISO-4869-3 on an acoustic test fixture.

[0094] A curve 1002 provides the standard deviation of the attenuation performance of the cushion component of the present disclosure and a curve 1004 provides the standard deviation of the attenuation performance of the existing reference cushion. The graph 1000 shows that a reduced variation in the attenuation performance was observed in testing the cushion component of the present disclosure as compared to the existing reference cushion. This is evident from the relatively low standard deviation in the attenuation performance of the cushion component of the present disclosure, especially in the frequency range of 200-2000 Hz.

[0095] In the present detailed description of the preferred embodiments, reference is made to the accompanying drawings, which illustrate specific embodiments in which the invention may be practiced. The illustrated embodiments are not intended to be exhaustive of all embodiments according to the invention. It is to be understood that other embodiments may be utilized, and structural or logical changes may be made without departing from the scope of the present invention. The following detailed description, therefore, is not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims.

[0096] Unless otherwise indicated, all numbers expressing feature sizes, amounts, and physical properties used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the foregoing specification and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by those skilled in the art utilizing the teachings disclosed herein.

[0097] As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” encompass embodiments having plural referents, unless the content clearly dictates otherwise. As used in this specification and the appended claims, the term “or” is generally employed in its sense including “and / or” unless the content clearly dictates otherwise.

[0098] Spatially related terms, including but not limited to, “proximate,” “distal,” “lower,” “upper,” “beneath,” “below,” “above,” and “on top,” if used herein, are utilized for ease of description to describe spatial relationships of an element(s) to another. Such spatially related terms encompass different orientations of the device in use or operation in addition to the particular orientations depicted in the figures and described herein. For example, if an object depicted in the figures is turned over or flipped over, portions previously described as below or beneath other elements would then be above or on top of those other elements. As used herein, when an element, component, or layer for example is described as forming a

[0099] “coincident interface” with, or being “on,” “connected to,” “coupled with,” “stacked on” or “in contact with” another element, component, or layer, it can be directly on, directly connected to, directly coupled with, directly stacked on, in direct contact with, or intervening elements, components or layers may be on, connected, coupled or in contact with the particular element, component, or layer, for example. When an element, component, or layer for example is referred to as being “directly on,” “directly connected to,” “directly coupled with,” or “directly in contact with” another element, there are no intervening elements, components, or layers for example.

[0100] Various examples have been described. These and other examples are within the scope of the following claims.

[0101] CLAIMS:

[0102] 1. A hearing protection device comprising: a headband; and a pair of earmuffs coupled to opposing ends of the headband, each earmuff from the pair of earmuffs comprising: a cushion; an ear cup comprising a support plate, wherein the cushion is coupled to the support plate; and a seal component that seals the cushion to the support plate and the ear cup, the seal component comprising an elastic material.

[0103] 2. The hearing protection device of claim 1, wherein the cushion is removable from the ear cup.

[0104] 3. The hearing protection device of claim 2, wherein the support plate comprises the elastic material, and wherein the seal component comprises a portion of the support plate.

[0105] 4. The hearing protection device of claim 3, wherein the support plate comprises a top surface defining a support plate axis along a length of the support plate, and wherein the seal component comprises an upper portion disposed above the support plate axis and a lower portion disposed below the support plate axis.

[0106] 5. The hearing protection device of claim 1, wherein the cushion is coupled to the support plate via a mechanical coupling.

[0107] 6. The hearing protection device of claim 5, wherein the mechanical coupling comprises a snap.

[0108] 7. The hearing protection device of claim 1, wherein the cushion is permanently coupled to the support plate.

[0109] 8. The hearing protection device of claim 7, wherein the cushion is coupled to the support plate by adhesive or welding.

Claims

9. The hearing protection device of claim 7, wherein the support plate comprises the elastic material.

10. The hearing protection device of claim 7, wherein the support plate comprises the seal component.

11. The hearing protection device of claim 1, wherein the support plate comprises an inelastic material.

12. The hearing protection device of claim 11 , wherein the seal component is coupled to the support plate.

13. The hearing protection device of claim 12, wherein the seal component is co-molded with the support plate.

14. The hearing protection device of claim 11, wherein the support plate comprises a top surface defining a support plate axis along a length of the support plate, wherein the seal component comprises an upper portion disposed above the support plate axis and a lower portion disposed below the support plate axis, and wherein the cushion is at least partially received between the upper portion and the lower portion of the seal component.

15. The hearing protection device of claim 11, wherein the cushion comprises a solid foam material, and wherein the cushion comprises the seal component.

16. The hearing protection device of claim 15, wherein the cushion is coupled to the support plate by an adhesive or welding.

17. The hearing protection device of claim 15, wherein the cushion is co-molded with the support plate.

18. The hearing protection device of claim 11 , wherein the cushion comprises an elastomeric shell.

19. The hearing protection device of claim 18, wherein the cushion comprises the seal component.

20. The hearing protection device of claim 11, wherein the support plate is coupled to the cushion by a snap.

21. The hearing protection device of claim 11, wherein the support plate is glued or welded to the cushion.

22. The hearing protection device of claim 1, wherein the cushion comprises a foam.

23. The hearing protection device of claim 1, wherein the cushion comprises an air-fdled elastomeric material.

24. An earmuff for a hearing protection device, the earmuff comprising: an ear cup comprising a hollow space; a cushion; a support plate configured to couple the cushion to the ear cup; and a seal component configured to seal the cushion to the support plate and the ear cup, wherein the seal component comprises an elastic material.

25. The earmuff of claim 24, wherein the cushion is permanently coupled to the support plate.

26. The earmuff of claim 25, wherein the cushion is coupled to the support plate by an adhesive or welding.

27. The earmuff of claim 25, wherein the cushion is co-molded with the support plate.

28. The earmuff of claim 24, wherein the cushion comprises the seal component.

29. The earmuff of claim 24, wherein the support plate comprises the seal component.

30. The earmuff of claim 24, wherein the support plate comprises a top surface defining a support plate axis along a length of the support plate, and wherein the seal component comprises an upper portion disposed above the support plate axis and a lower portion disposed below the support plate axis.

31. The earmuff of claim 30, wherein the support plate is at least partially received between the upper portion and the lower portion of the seal component.

32. The earmuff of claim 30, wherein the cushion is at least partially received between the upper portion and the lower portion of the seal component.

33. The earmuff of claim 30, wherein the cushion comprises the seal component.

34. The earmuff of claim 30, wherein the support plate comprises the seal component.

35. The earmuff of claim 24, wherein the cushion comprises a groove, and wherein the groove at least partially receives the seal component therein.

36. The earmuff of claim 24, wherein the cushion comprises a foam.

37. The earmuff of claim 24, wherein the cushion comprises an elastomeric shell.

38. The earmuff of claim 24, wherein the seal component directly contacts the ear cup.

39. The earmuff of claim 24, wherein the seal component deforms when the cushion is sealed to the support plate and the ear cup.

40. A cushion component for an earmuff comprising: a cushion comprising a resilient and deformable material, wherein the cushion comprises a first coupling portion; a support plate coupled to the cushion, wherein the support plate is made of a hard material; a seal component configured to seal the cushion to the support plate and an ear cup, wherein the seal component comprises a second coupling portion configured to couple to the first coupling portion; and a coupling mechanism configured to couple the cushion to the ear cup, wherein the seal component deforms when the cushion is coupled to the ear cup.

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