Corded Earplugs With Tapered Mechanical Locking
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Solution Overview
Problem
Existing methods for attaching cords to earplugs are cumbersome, relying on adhesive bonds that may not be strong and are permanent, making it difficult to insert the cord during adhesive liquidity and limiting the earplugs' usability without the cord.
Innovation Solution
A method involving a flexible cord and earplugs with angularly or physically displaced openings, where the cord is looped through these openings to create a secure attachment that can be easily reversed for detachment, using a braided or elastomeric material for the cord and earplugs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive bonding method is used to attach cord to earplug, then attachment strength may be improved, but the process complexity increases and the attachment becomes permanent
Solution Approach 1:
The patent replaces the chemical adhesive bonding system with a mechanical locking system. The cord is inserted through a tapered hole in the earplug, and the taper geometry creates a mechanical interference fit that locks the cord in place. This mechanical approach eliminates the need for adhesive application processes while providing secure attachment through geometric constraints and friction.
Solution Approach 2:
Instead of applying adhesive to the cord and inserting it into the earplug opening, the patent inverts the process by inserting the cord through a tapered hole where the hole itself provides the bonding mechanism through its geometry. The cord is pulled through and locked by the taper shape, reversing the traditional adhesive-application sequence.
2Reliability
If adhesive bonding method is used to attach cord to earplug, then attachment can be made, but the attachment is permanent and cannot be removed
Solution Approach 1:
The patent creates a dynamic attachment system where the cord can be securely held during use through the tapered mechanical lock, but can also be easily removed by pulling the cord through the tapered hole in reverse. The same geometric feature that provides secure attachment during use enables easy removal when needed, providing adaptability.
3Productivity
If cord is inserted during short adhesive liquid time, then attachment can be made, but the operation difficulty increases
Solution Approach 1:
By replacing the time-sensitive adhesive process with a mechanical tapered-hole insertion system, the patent eliminates the constraint of working within the short adhesive liquid time window. The mechanical system allows the cord to be inserted and locked at any time without rushing, significantly improving ease of operation while maintaining attachment speed.
Data Source
AI summary
An apparatus and a method of making a corded earplug, including a flexible cord material and a pair of earplugs. Each earplug has a nose portion for insertion into the ear and a rear portion extending from the nose portion and lying outside of the ear when the nose portion is inserted into the ear. Each rear portion has a pair of openings physically displaced from each other and/or angularly displaced from each other. At least one of the openings extends through the rear portion. A short portion of the flexible cord material is inserted through the at least one opening extending through the rear portion. The short portion of the flexible cord material is then inserted into the other opening to have the short portion of the flexible cord material physically displaced and/or angularly displaced along its length to lock the flexible cord material to the rear portion of the earplug.