Modular Earplug with Acoustic Resonance Channel
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Solution Overview
Problem
One-size-fits-most hearing protection devices that aim to deliver minimally distorted sound at an affordable price often fail to achieve suitable levels of protection or sound quality due to improper use and lack of a proper fit, while custom devices are cost-prohibitive.
Innovation Solution
A cost-effective earplug device with an intracanal sealing system and integral external concha tab, utilizing elastomeric materials for proper fit and comfort, and an acoustic resonance channel tube to maintain sound quality, which includes an attenuating filter to minimize distortion and occlusion effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If one-size-fits-most hearing protection devices are used, then cost is reduced, but fit and sound quality deteriorate
Solution Approach 1:
The device is divided into multiple seal portions (outer seal, middle seal, inner seal) with different sizes and configurations. Users can select and combine different seal portions to achieve a proper fit for their specific ear canal dimensions, transforming a single-size device into a multi-configurable solution that maintains manufacturing efficiency while improving fit precision.
2Ease of manufacture
If one-size-fits-most hearing protection devices are used, then cost is reduced, but sound quality deteriorates
Solution Approach 1:
The device incorporates multiple seal portions with varying densities, porosities, and acoustic transmission properties. Different seal portions are optimized for specific functions (attenuation, comfort, sound transmission), allowing the device to maintain high sound quality by selecting the appropriate combination of seal portions while keeping manufacturing costs low through modular design.
3Manufacturing precision
If custom molded devices are used, then fit and sound quality are improved, but cost increases
Solution Approach 1:
The device provides universal applicability across different user populations by offering multiple seal portion sizes and types that can be mixed and matched. This modular approach eliminates the need for custom molding while achieving personalized fit and sound quality, as users can select the combination of seal portions that best suits their individual ear canal characteristics.
4Manufacturing precision
If multiple seal portions are provided for selection, then fit is improved, but device complexity increases
Solution Approach 1:
The device extracts the sealing function into separate, interchangeable seal portions that can be independently selected and removed. This separation simplifies the overall device structure by allowing users to choose only the necessary seal portions for their needs, reducing the complexity of having to design a completely different device for each user configuration.
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 device effectively attenuates environmental sounds to safe levels without compromising sound quality, providing optimal hearing protection and cosmetic appeal, suitable for most users without the need for custom molding.
Implementation Method 1
an acoustic resonance channel tube, which allows sound to reach the tympanic membrane and maintain sound quality appropriate for listening to music and speech
Implementation Method 2
The device can attenuate environmental sounds to a safe level, for example, typically less than 85 dB sound pressure levels in the ear
Data Source
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AI summary
The present disclosure describes a cost-effective earplug device that delivers minimally distorted sound, offers sound protection, can fit most users, and can protect human hearing from dangerously-high acoustic levels without the cost or inconvenience of a custom earplug.