Custom Earpiece Dispensing System with Balloon

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Contemporary hearing protection devices, such as headsets and earplugs, are often bulky, uncomfortable, and prone to being knocked off, leading to reduced noise reduction effectiveness due to improper sealing, and custom earpieces require complex mixing and insertion procedures that can be error-prone and uncomfortable.

Innovation Solution

A two-component dispensing system with a mixer and balloon that ensures proper mixing and insertion of a silicon compound into the ear canal, eliminating the need for manual mixing and minimizing the risk of eardrum contact, while the balloon defines the earpiece shape and limits insertion depth.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If custom earpieces are made using traditional manual mixing methods, then the earpieces can be tailored to fit individual ear canals, but the process becomes complex and error-prone requiring multiple measurements, material selection, and manual mixing steps

Engineering Contradiction:

Improveearpiece fit precisionVSAvoidmixing process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The compound is divided into two separate components stored in separate chambers of the syringe, which are mixed automatically during dispensing. This segmentation allows for precise control of material delivery while simplifying the overall process by eliminating manual mixing steps.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mixing action is performed automatically by the dispensing system itself as the two components are forced together through the mixing chamber during syringe operation. This self-service approach eliminates the need for external manual mixing while ensuring consistent and precise proportioning.

Inventive Principle:

Principle #25Self-service

2Reliability

If the compound is inserted deep into the ear canal to ensure proper sealing, then noise reduction effectiveness is improved, but the risk of contacting the eardrum and causing discomfort or damage increases

Engineering Contradiction:

Improvenoise reduction effectivenessVSAvoideardrum contact risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

A balloon is introduced as an intermediary carrier that receives the compound in its inflated state within the ear canal. The balloon expands to push the compound to the desired depth for effective sealing while the balloon structure itself prevents direct contact between the compound and the eardrum, thereby eliminating the harmful effect.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The balloon acts as a flexible shell that contains and transports the compound. Its elasticity allows it to be inflated to the required size and position, providing a protective barrier that prevents the compound from contacting the eardrum while still achieving proper insertion depth for noise reduction.

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If two-component compounds are used to ensure proper curing and fit, then earpiece effectiveness is improved, but the risk of improper mixing proportions and material selection increases

Engineering Contradiction:

Improveearpiece effectivenessVSAvoidmixing proportion accuracy

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The two-component compound is stored in separate chambers within the syringe, with each component isolated until dispensing. This segmentation ensures that the correct components are used in the correct proportions automatically during the dispensing process, eliminating errors in material selection and proportioning.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The syringe mechanism provides inherent feedback control for dispensing the two components in precise, equal proportions. The mechanical coupling of the syringe plunger ensures that both components are delivered at the same rate and quantity, providing automatic proportioning control without manual measurement.

Inventive Principle:

Principle #23Feedback

4Adaptability or versatility

If manual mixing of two-component compounds is performed, then flexibility in material selection is maintained, but the process becomes time-consuming and prone to errors

Engineering Contradiction:

Improvematerial selection flexibilityVSAvoidmixing process time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The two components are pre-loaded into separate chambers of the syringe in the correct proportions before use. This preliminary preparation eliminates the need for on-site mixing and measurement, allowing the user to simply activate the syringe to receive the pre-measured and pre-mixed components instantly.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS7934916B2Custom earpiece

Publication Date: 2011.05.03 SUREFIRE LLC

AI summary

A system for making custom earpieces is disclosed. The system can include a two-component dispensing container such as a two-component syringe or a two-component squeeze bulb. The two components stored in the two-component dispensing container are kept separate until they are dispensed. The two components can be dispensed into a balloon disposed within the ear canal of a user. The two components can define an earpiece after they are dispensed into the balloon. A mixer mixes the two components as they are dispensed. The balloon can be attached to the two-component dispensing container such that two components enter the balloon after the two components are mixed. In this manner, a more comfortable and effective custom earpiece can be made more safely and more conveniently.