Push-in Earplug with Removable Mandrel for Channel Formation
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Solution Overview
Problem
The manufacturing of push-in earplugs with a through-hole poses challenges due to the need to create a shaped sound attenuating portion that enters the user's ear, and existing methods require complex tooling and manual effort to support hollow preforms during molding.
Innovation Solution
A push-in earplug design featuring a removable mandrel made of fluoropolymer, such as PTFE or FEP, which extends throughout the earplug to form a channel, allowing for easy removal without deformation and eliminating the need for additional tooling or manual support, with a foamable outer layer that thermally bonds to a semi-rigid core to create a sound attenuating portion and stem portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complex tooling and manual support are used to create hollow preforms during molding, then manufacturing precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent removes the complex tooling and manual support requirements by using a self-supporting hollow preform structure that maintains its shape during molding without additional equipment, thereby reducing device complexity while preserving manufacturing precision
Solution Approach 2:
The hollow preform is designed with pre-formed structural features that provide self-support during the molding process, eliminating the need for complex tooling and manual intervention while ensuring precise manufacturing outcomes
2Ease of operation
If the sound attenuating portion is compressed before insertion, then ease of operation is improved, but hygiene is worsened due to increased contact with the attenuating portion
Solution Approach 1:
The earplug is divided into distinct functional zones: a stiff stem portion for handling and insertion, and a separate compressible sound attenuating portion for ear canal insertion, allowing the user to grip the stem without contacting the attenuating portion, thus improving hygiene while maintaining ease of insertion
Solution Approach 2:
The stiff stem portion acts as an intermediary between the user's hand and the sound attenuating portion, allowing force application for insertion without direct contact with the attenuating portion, thereby improving both ease of operation and hygiene
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enables efficient and cost-effective manufacturing of earplugs with a channel, promoting hygiene by eliminating the need to compress the sound attenuating portion before insertion and allowing for customizable frequency response through the use of filters or acoustic devices.
Implementation Method 1
an outer layer comprising a foamable material, the outer layer covering at least a portion of an outer surface of the elongate core
Implementation Method 2
a foamable outer layer that thermally bonds to a semi-rigid core to create a sound attenuating portion and stem portion
Data Source
AI summary
A push-in earplug is provided. The push-in earplug comprises an elongate core comprising a core material. The push-in earplug also comprises an outer layer comprising a foam material, the outer layer covering at least a portion of an outer surface of the elongate core. The push-in earplug also comprises a channel extending through the elongate core from a first end of the elongate core to the second end of the elongate core.