Dual-Polymer Ear Plug Structure for Comfort and Secure Fit
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Solution Overview
Problem
Existing ear plugs face challenges in providing physical comfort, easy assembly and disassembly, and maintaining a secure fit while being comfortable to wear, due to conflicting requirements such as firm connection and ease of use.
Innovation Solution
The ear plug design incorporates a substrate made of a harder polymer with a softer silicone polymer covering layer, featuring a non-circular stem cross-section and a tubular ear tip with a foamed polymer filling, ensuring a secure fit and comfortable wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the ear plug uses a single hard polymer material, then it provides firm connection and structural strength, but it reduces physical comfort and skin contact tolerance
Solution Approach 1:
The ear plug applies local quality by using a harder polymer for the stem portion requiring structural strength and connection force, while covering the distal portion with a softer silicone polymer for comfort and skin contact tolerance. This spatial differentiation of material properties resolves the contradiction between strength and comfort.
Solution Approach 2:
The ear plug uses composite materials by combining a harder polymer substrate with a softer silicone polymer covering layer. This composite structure allows the harder polymer to provide structural integrity and connection force while the softer silicone layer provides physical comfort and skin tolerance, simultaneously satisfying both requirements.
2Ease of operation
If the ear plug uses a single soft polymer material, then it provides physical comfort and skin contact tolerance, but it reduces structural strength and connection force
Solution Approach 1:
The ear plug applies local quality by using a harder polymer for the stem portion requiring structural strength and connection force, while covering the distal portion with a softer silicone polymer for comfort and skin contact tolerance. This spatial differentiation of material properties resolves the contradiction between strength and comfort.
Solution Approach 2:
The ear plug uses composite materials by combining a harder polymer substrate with a softer silicone polymer covering layer. This composite structure allows the harder polymer to provide structural integrity and connection force while the softer silicone layer provides physical comfort and skin tolerance, simultaneously satisfying both requirements.
3Ease of operation
If the ear plug stem is completely covered with polymer material, then it provides smooth surface and comfort, but it reduces ease of assembly and disassembly
Solution Approach 1:
The ear plug applies local quality by providing a silicone polymer covering layer on the distal portion of the stem for comfort, while leaving the proximal portion of the stem free of covering for easy assembly and disassembly. This spatial differentiation allows both comfort and ease of assembly to coexist.
Data Source
Figure 1~2
Figure 3~4
Figure 5a~5b
AI summary
An ear plug (100) comprises an outer ear part comprising a stem (110). The ear plug (100) comprises an ear tip (200) coupled to the stem (110) of the outer ear part an ear tip (200) coupled to the stem (110). The outer ear part comprises: - a substrate (102) defining the shape and providing the stem (110) of the ear plug (100), the substrate (102) comprising a first and a second portion (111, 112); and - a covering layer (120) covering said first portion (111) of the substrate (102) and providing the outer surface of said first portion (111), the outer end (113) of the stem (110) being provided by the second portion (112) of the substrate (102) and being adapted to be inserted in the ear tip (200), said second portion (112) being free of said covering layer (120). The substrate (102) is provided from a first polymer, the covering layer (120) being provided from a second polymer being a silicone polymer, the hardness of the first polymer being larger than the hardness of the second polymer.