Integral Handle Earplug for Reduced Sound Attenuation
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Solution Overview
Problem
Existing hearing protection devices, such as push-in and roll-down earplugs, often provide excessive sound attenuation, making it difficult to allow desired sounds to penetrate in low-noise environments and are uncomfortable due to rigid components, with complex insertion methods leading to inconsistent and reduced sound reduction ratings.
Innovation Solution
A novel earplug design featuring a partially inserted, compressible resilient material with an integral handle for easy insertion and reduced attenuation, eliminating the need for separate manufacturing and assembly of components, allowing for a consistent Single Number Rating (SNR) of 15 to 25.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a rigid or semi-rigid portion is added to a push-in earplug to facilitate insertion, then ease of operation is improved, but device complexity and manufacturing cost increase due to separate component assembly
Solution Approach 1:
The patent combines the insertion facilitator and the earplug body into a single integral component. The earplug consists of a compressible resilient body with an embedded rigid or semi-rigid insertion facilitator that is formed together with the body in a single manufacturing process, eliminating the need for separate assembly operations.
Solution Approach 2:
The single component serves multiple functions: the compressible resilient body provides sound attenuation when inserted into the ear canal, while the embedded rigid or semi-rigid portion facilitates insertion by providing a grip and pushing force. This multi-functional design eliminates the need for separate components.
2Reliability
If traditional push-in earplugs are used to provide high sound attenuation, then hearing protection is improved, but the ability to hear desired sounds in low-noise environments deteriorates
Solution Approach 1:
The patent enables partial insertion of the earplug into the ear canal. By inserting only a portion of the compressible resilient body into the canal while leaving the remainder outside, the user can achieve reduced sound attenuation (SNR of 15-25) that allows desired sounds to be heard while still providing adequate hearing protection in low-noise environments.
3Ease of manufacture
If roll-down earplugs are used to reduce insertion complexity, then ease of manufacture is improved, but insertion precision and consistent occlusion deteriorate
Solution Approach 1:
The rigid or semi-rigid insertion facilitator is pre-formed and embedded within the compressible resilient body during manufacturing. This preliminary preparation of the insertion facilitator ensures that the earplug is ready for precise and consistent insertion without requiring complex roll-down procedures or manual manipulation during use.
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
The earplug provides a comfortable, simple insertion method with consistent reduced sound attenuation, ensuring adequate hearing protection without excessive noise reduction, allowing desired sounds to be audible in low-noise environments.
Implementation Method 1
the sound attenuating portion compresses, as necessary, upon entry into the ear canal and is held therein by a friction fit
Implementation Method 2
the sound attenuating portion compresses, as necessary, upon entry into the ear canal and is held therein by a friction fit
Data Source
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AI summary
The invention provides an earplug and a method of forming thereof where the earplug includes an insertion portion having opposing top and bottom sides, a handle portion connected to and extending rearwardly from the bottom of the insertion portion, and a rear portion extending from the top of the insertion portion to the handle portion, where the insertion portion is configured to be partially inserted into an ear canal of a wearer, where the handle portion remains at least partially extending from the earcanal for use in handling the earplug, and where the insertion portion and the handle portion are integrally formed of a resilient compressible material.