Flexible Multi-Mic Earphone Assembly for Secure Concha Fit
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Solution Overview
Problem
Existing earphones often fail to provide a secure fit in the concha due to a fixed angle between the ear insert and the earphone, leading to discomfort and poor sound isolation, especially in noisy environments where ambient and internal acoustic noise are challenging to mitigate.
Innovation Solution
The use of a flexible earphone design with two microphones - one for ambient sound and one for the ear canal - combined with a customizable eartip that distributes contact force and provides enhanced sound isolation, using materials like silicone and 3D printing for optimal fit and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a fixed angle design is used for the earphone, then the manufacturing is simplified, but the earphone cannot fit properly in the concha of the ear
Solution Approach 1:
The earphone incorporates a flexible neck portion that can bend and adapt to different ear canal angles. This dynamic flexibility allows the earphone to adjust to the unique angle between the ear canal aperture and concha plane for each individual, resolving the contradiction between simplified manufacturing and proper fit adaptability.
Solution Approach 2:
The design changes the angular parameter of the earphone by allowing the flexible neck to assume different bending angles. This enables the earphone to match the varying concha-aperture angles between individuals while maintaining a standardized manufacturing process for the rigid portions.
2Device complexity
If a single microphone is used, then the device complexity is reduced, but the ability to pick up vocal cues and mitigate ambient noise is insufficient
Solution Approach 1:
The audio detection function is segmented into two separate microphones: one positioned to capture ambient sound and another to capture sound within the ear canal. This segmentation allows each microphone to specialize in its specific acoustic environment, improving vocal cue detection and noise mitigation while keeping the overall system relatively simple.
Solution Approach 2:
The system uses the difference in acoustic signals between the two microphones as an intermediary to identify and isolate vocal cues from ambient noise. By comparing the ambient microphone signal with the ear canal microphone signal, the system can distinguish user vocalizations from environmental sounds.
3Manufacturing precision
If a rigid eartip design is used, then the manufacturing precision is improved, but the contact force distribution is poor causing discomfort
Solution Approach 1:
The eartip is designed as a flexible, compliant structure that can deform to match the contours of the user's ear canal. This flexibility allows the eartip to distribute contact force evenly across the ear canal walls, improving comfort while maintaining manufacturability through standard molding processes.
Data Source
AI summary
At least one exemplary embodiment is directed to a method of earphone manufacturing with an ear canal microphone, ambient sound microphone and a speaker, where the earphone has parts that have been 3D printed.