Variable Wall Earbud Flange for Secure Fit and Comfort
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Solution Overview
Problem
Existing earbud designs fail to provide optimal comfort, audio quality, and durability while maintaining a secure fit in the ear canal for various audio devices such as earphones, stethoscopes, and hearing aids.
Innovation Solution
The earbud design features an annular flange with a tapered exterior surface and varying wall thickness, an acoustic channel of specific diameters, and materials like polymers or elastomeric polymers for flexibility and comfort, ensuring a secure fit and effective sound transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the earbud uses a uniform wall thickness design, then the manufacturing process is simple, but the comfort and secure fit in the ear canal are compromised
Solution Approach 1:
The patent applies local quality by varying the wall thickness of the annular flange at different locations. The flange has a first wall thickness in a first region and a second wall thickness in a second region, allowing different areas to serve different functions: thicker regions provide structural support and durability, while thinner regions enhance comfort and flexibility for ear canal fit. This resolves the contradiction by making the structure non-uniform to simultaneously achieve manufacturing feasibility and operational comfort.
Solution Approach 2:
The patent implements dynamics by making the earbud structure adaptable to different ear canal shapes and sizes. The varying wall thickness allows the flange to flex and conform to the unique anatomy of each user's ear, providing a secure fit while maintaining structural integrity. This dynamic adaptation resolves the contradiction between simple manufacturing and customized comfort.
2Reliability
If the earbud uses a larger diameter acoustic channel, then the sound transmission is improved, but the fit and security in the ear canal deteriorate
Solution Approach 1:
The patent applies local quality by optimizing the acoustic channel diameter independently from the flange outer dimensions. The acoustic channel has a specific diameter range (0.6mm to 1.5mm) that is tailored for optimal sound transmission, while the flange outer diameter (6mm to 12mm) is optimized for secure fit. This localized optimization of different regions resolves the contradiction between sound quality and fit security.
Solution Approach 2:
The patent resolves the contradiction by transitioning from a single-dimension design to a multi-dimensional design. Instead of increasing overall size to improve sound transmission, the patent optimizes the internal acoustic channel dimensions independently from the external flange dimensions. This dimensional separation allows the acoustic channel to be sized for sound quality while the external dimensions maintain secure fit.
3Strength
If the earbud uses rigid materials, then the durability is improved, but the comfort and flexibility deteriorate
Solution Approach 1:
The patent applies composite materials by using polymers or elastomeric polymers that combine the properties of rigidity and flexibility. These materials provide the necessary structural strength and durability while simultaneously offering the flexibility and comfort needed for ear canal fit. The composite nature of these materials resolves the contradiction between durability and comfort by integrating both properties into a single material system.
Solution Approach 2:
The patent implements parameter changes by selecting materials with specific mechanical properties that balance strength and flexibility. The use of polymers with controlled durometer values allows the earbud to maintain structural integrity for durability while providing sufficient flexibility for comfort. This parameter optimization resolves the contradiction between strength and flexibility.
Data Source
AI summary
An ear tip is disclosed that comprises an annular flange having a first end tapering downwardly to a second end and having a circular lateral cross-section. The annular flange is defined by a plurality of sections and each section has a varying wall thickness. An inner body extends internally from the first end within a hollow interior defined by the annular flange toward the second end. An acoustic channel extends through the inner body, where the annular flange at least partially occludes an ear canal from ambient noise and creates at least a partial air seal in the ear canal and the acoustic channel is configured to allow the passage of sound into the ear canal when the inner body is connected with a sound source.