Curved Earplug Stem Rotates to Fit Canal Geometry
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing pre-molded push-in earplugs struggle to accommodate the variability in human ear canal size and geometry, often causing discomfort due to stem contact with the sidewalls during insertion and wear, and require manual bending which increases pressure.
Innovation Solution
A push-in earplug with a crooked or wavy stem configuration that can be rotated during insertion to fit around curved ear canal sections, minimizing contact with the sidewalls and accommodating various ear shapes without the need for bending, using a handle portion for easy manipulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a straight stiff plastic stem is used for insertion, then the earplug structure is simple and manufacturing is easy, but the stem contacts the sidewalls of the curved ear canal causing discomfort and irritation
Solution Approach 1:
The patent applies curvature to the stem by providing a curved section that follows the natural curvature of the ear canal. This curved stem configuration allows the stem to navigate the curved path of the ear canal without contacting the sidewalls, thereby maintaining insertion comfort while remaining manufacturable through standard molding processes.
2Ease of operation
If the stem is made flexible to accommodate curved ear canals, then insertion comfort is improved, but the stem may bend inside the ear canal increasing pressure and causing discomfort
Solution Approach 1:
The stem is segmented into distinct functional sections: a rigid insertion portion that provides structural support and control, and a curved adaptation section that follows the ear canal geometry. This segmentation allows the stem to maintain its shape and avoid excessive bending while still accommodating the curved path of the ear canal, thereby reducing pressure on the ear canal walls.
3Ease of manufacture
If a single type of pre-molded earplug is used, then manufacturing is simple and cost-effective, but it cannot accommodate the broad range of human ear canals in both size and geometry
Solution Approach 1:
The earplug design incorporates a universal curved stem configuration that can adapt to various ear canal geometries and sizes. The curved stem section is designed with specific curvature parameters that allow it to follow the natural path of different ear canals, making a single earplug type suitable for a broad range of users while maintaining simple manufacturing processes.
4Reliability
If the stem is manipulated to insert the front end to the proper position for maximum attenuation, then sound blocking is improved, but the stem touches the sidewall of the ear canal causing irritation
Solution Approach 1:
The curved stem configuration enables the earplug to be inserted along the curved path of the ear canal without the stem contacting the sidewalls. This allows the front end to reach the proper position for maximum sound attenuation while the curved geometry prevents sidewall contact, thereby eliminating irritation while maintaining effective noise blocking.
Data Source
Figure 1~3
Figure 4~7
Figure 8~9(A)
AI summary
A hearing protective earplug for insertion into the human ear canal of a user where the human ear canal has sidewalls and a typical curved portion. A soft resilient body has a main body element with a front end for insertion in the human ear canal. An elongated stem has two ends with one end attached to the main body element. The stem extends outward from the main body element and away from the front end. The other end of the stem forms a handle portion of the stem. The stem is sufficiently stiff as to allow manipulation of the main body element into the ear canal of the user. The stem member has a crooked or wavy configuration within the ear canal as it extends outward from the main body to the handle portion of the stem. As the front end of the main body element is inserted into the ear canal, the stem member is rotated during insertion with the handle portion to fit around the typical curved portion in the human ear canal. This seats the main body to acoustically block the ear canal while at the same time spaces the stem member within the typical curved portion of the ear canal to minimize contact with the sidewalls of the ear canal.