Technical Field

[001] The present invention relates to an ear cover and, in one form, to a sound attenuating ear cover for use by a user when sleeping.

Background Art

[002] Ear covers are used in many different environments, such as in high or repetitive noise environments like construction or building sites. Such ear covers, to provide sound attenuation, are bulky, heavy and can become uncomfortable if worn for long periods. Such bulkiness is however required in order to obtain the desired sound attenuation.

[003] Ear covers are also sometimes worn by people wanting to sleep or otherwise relax. For example, shift workers may need to sleep during the day when the ambient level of noise is relatively high, or travellers may want to sleep or at least reduce the ambient noise so they can relax during long periods of travel. Ear covers such as those discussed above are however uncomfortable for a user to wear whilst sleeping or relaxing.

[004] It would be advantageous to provide comfortable but effective ear covers for a user to wear whilst sleeping or relaxing.

Disclosure of Invention

[005] In one aspect, the invention provides a sound attenuating ear cover for wearing while sleeping (or relaxing). The ear cover comprises an ear encompassing portion formed from a first material. The first material has a hardness whereby the ear encompassing portion is substantially conformable to a surface onto which it is pressed, and a resiliency whereby the ear encompassing portion defines an ear encompassing shape when not pressed onto the surface.

[006] The ear encompassing portion of the sound attenuating ear cover of the invention is formed from a material having a hardness and resiliency that enables it to conform to surfaces onto which it is pressed (e.g. pillows, seat rests, etc.) but retain an ear encompassing shape (i.e. a shape which comfortably accommodates a user's ear) otherwise. Thus, a user's ear can be comfortably accommodated within the ear encompassing portion when not pressed against a surface and, when pressed against a surface (e.g. when the user lies down and puts their head on a pillow), even though the ear encompassing shape is no longer defined by the ear encompassing portion, its ready deformability to (roughly) conform to the surface provides a degree of comfort to the user not achievable with ear covers having conventional (harder) materials. A sound attenuating, soft, pliable, and hence relatively comfortable, ear cover is provided.

[007] The hardness of a material can be measured using durometer scales. There are a number of scales of durometer, which can be used to measure the hardness of different materials. For example, the Shore A durometer scale provides a measure of the hardness of polymeric materials. The first material from which the ear encompassing portion may be formed can, for example, have a hardness of between about 20 to about 90 on the Shore A durometer scale. In another form, the first material can have a hardness of between about 30 and about 80, or about 30 and about 60 on the Shore A durometer scale. In yet another form, the first material can have a hardness of between about 40 and about 50 on the Shore A durometer scale. It will be appreciated that the hardness of the first material could be measured using other appropriate durometer scales.

[008] In one form, the first material is a silicone based material. Silicone based materials such as medical grade silicone materials, for example, have been found by the inventor to be suitable for use in the invention.

[009] In one form, the ear encompassing portion can have a slippery outer coating. A slippery outer coating can help to prevent the ear cover from sticking to or becoming caught on surfaces such as pillows, which may hinder the natural movement of a user's head during sleep.

[0010] In one form, the ear encompassing portion comprises at least one channel for receiving a strap therethrough. The strap can be used, for example, to attach two ear encompassing portions together such that the straps comfortably hold the ear encompassing portions in position over a user's ears during use.

[0011] In one form, the ear encompassing portion comprises at least one aperture for equalising pressure on both sides (i.e. inside and outside) of the ear cover. That is, air is able to move into and out of the space around the user's ear via the aperture, which prevents any uncomfortable pressure build up or vacuum occurring inside the ear cover during use, especially as the user presses the ear cover against a surface (e.g. a pillow).

[0012] In some forms, the ear cover further comprises a user contacting portion formed from a second material. The second material is softer than the first material and conformable to a user's head, which can provide an even greater degree of comfort and sound attenuation. [0013] The hardness of the second material can, for example, be measured using a Durometer scale such as the Shore-00 durometer scale (which is one of the scales for measuring softer materials). However, the hardness of the second material could be measured on other durometer scales. In one form, the second material can have a hardness between about 20 and about 80, or between about 20 and about 50 on the Shore-00 durometer scale. In another form, the second material can have a hardness between about 40 and about 80, or between about 30 and about 50 on the Shore-00 durometer scale. In yet another form, the second material can have a hardness between about 40 and about 50 on the Shore-00 durometer scale.

[0014] In one form, the second material is a sound attenuating form. The second material may, for example, be a closed cell foam such as an elastic polyurethane foam (e.g. a viscoelastic polyurethane foam) or a polyvinyl chloride foam.

[0015] In one form, the second material can be a single material. In another form, the second material may comprise a number of laminate materials.

[0016] In one form, the ear cover further comprises an insulator adapted to be received within the ear encompassing portion. The insulator can provide additional sound insulation where such is required. In some forms, the insulator may be able to be inserted and removed by a user in order to control the degree of sound attenuation of the ear cover. Such an insulator can, for example, be in the form of a foam block. Such an insulator can, for example, have a hardness of between about 40 and about 80 on the shore A durometer scale.

[0017] In one form, the ear cover further comprises a mask for covering a user's eyes.

[0018] In another aspect, the invention provides a sleep mask comprising two ear covers of the invention, as described herein, optionally in combination with a mask for covering a user's eyes.

Brief Description of the Drawings

[0019] Specific embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:

[0020] Figure 1 is an exploded view of an ear cover in accordance with an embodiment of the invention;

[0021] Figure 2A is a cross sectional view through an ear cover in accordance with an alternate embodiment of the invention;

[0022] Figure 2B is a cross sectional view through an ear cover similar to that of Figure

2A, but which includes a foam plate;

[0023] Figure 3 is a rear view of the ear covers of Figure 2; [0024] Figure 4A is a front perspective view of the ear cover of Figure 2B;

[0025] Figure 4B is an exploded perspective view of the ear cover of Figure 2B;

[0026] Figure 4C is a rear perspective view of the ear cover of Figure 2B;

[0027] Figure 5 is a side view of a user's head, on which an ear cover in accordance with an embodiment of the invention is positioned; and

[0028] Figure 6 is a side view of a user's head, on which an ear cover in accordance with an alternate embodiment of the invention is positioned.

Modes for carrying out the Invention

[0029] The invention relates to a sound attenuating ear cover for wearing while sleeping or relaxing. Specific embodiments of the invention will be described below with reference to the drawings, with various features of the invention being more generally described where relevant.

[0030] Referring firstly to Figure 1 , an ear cover 10 comprises an ear encompassing portion 12 formed from a first material and a user contacting portion 30 formed of a second material.

[0031] The first material has a resiliency that enables the ear encompassing portion 12 to define an ear encompassing shape (e.g. the chamber into which a user's ear can be received in Figure 1) in the absence of any compressive forces, but a hardness that enables it to be relatively readily deformable such that the shape of the ear encompassing portion 12 can substantially conform to a surface onto which it is pressed. The ear encompassing portion 12 thereby provides the user with a light and un-cumbersome feeling when relaxing and does not cause discomfort to the user when the weight of the user's head is placed on the ear cover 10 during sleep. In this manner, regardless of the surface against which the user's head (and ears) is positioned against, any discomfort caused by the ear encompassing portion 12 is minimised.

[0032] Whilst "hardness" might not be the most appropriate descriptive term for describing the properties of the ear encompassing portion and user contacting portion ("softness" may be a more appropriate term), these properties can be quantified by their hardness, so this term will be used throughout the specification.

[0033] Any material having sound attenuation properties and appropriate mechanical, elastic and hardness properties can be used as the first material. For example, the material used to form the ear encompassing portion 12 can have a hardness of between about 20 and about 90 on a Shore A durometer scale. In some embodiments, the material can have a hardness in the range of between about 30 to about 80, between about 40 and about 70, or between about 40 to about 50 on the Shore A durometer scale. As noted above, other durometer scales could be used to measure the hardness of the first material.

[0034] The ear encompassing portion 12 can, for example, be formed from a silicone based material (e.g. medical grade silicone rubber or silicone rubber with parylene), but could be formed from any other suitable material having the appropriate properties. For example, other suitable materials which could be used to form the ear encompassing portion 12 include thermoplastic polyester elastomers, materials with thermoplastic and elastomeric properties, rubbers (natural or synthetic) and viscoelastic polymers.

[0035] The ear encompassing portion 12 (and hence ear cover 10) has a low-profile (i.e. when worn by a user), generally rounded shape. However, it will be appreciated that ear covers in accordance with the present invention may have a wide variety of shapes, provided that they encompass a user's ears and provide some sound attenuation.

[0036] The ear encompassing portion 12 can also have a slippery outer coating to prevent the ear cover 10 from impeding a user's natural head movement during sleep. The slippery outer coating helps to prevent the ear cover 10 from being caught or snagged on surfaces such as pillow covers by lowering the frictional properties of the ear cover. The slippery outer coating may, for example, be provided by applying a slippery coating (e.g. a Teflon coating) on the outer (in use) surfaces of the ear cover 10. Alternatively a slippery outer cover may be provided by covering the outer surfaces of the ear cover with a slippery material such as satin.

[0037] The ear cover 10 also has a user contacting portion 30 formed of a second material. In ear cover 10, the second material is a foam such as a sound attenuating closed cell foam (e.g. a viscoelastic polyurethane foam or a polyvinyl chloride foam). However, it will be appreciated that other materials having appropriate properties could be used. User contacting portion 30 is softer than ear encompassing portion 12 and is readily deformable so as to conform to a user's head, thus providing a comfortable and sound attenuating interface between the user and the relatively harder (but still soft and pliable) ear encompassing portion 12. The user contacting portion may, for example, be a memory foam, that is, a foam which "remembers" its uncompressed shape, and returns to that shape in the absence of compressive forces (e.g. when the ear cover is not in use). Such a foam would also tend to conform closely to a user's head. As the user contacting portion 30 is supported by the ear encompassing portion 12, it does not require a hardness and resiliency similar to that of the ear encompassing portion 12.

[0038] Any material having an appropriate hardness (i.e. softer than the first material) and characteristics suitable for the intended use of the ear cover can be used. The hardness of the second material can be measured using a Durometer scale such as the Shore-00 durometer scale (or other appropriate durometer scale). In one embodiment, the second material can have a hardness in the range of between about 20 to about 80, or between about 20 to about 50 on the Shore-00 durometer scale. In another embodiment, the second material can have a hardness in the range of between about 30 to about 50 on the Shore-00 durometer scale. In another embodiment, the second material can have a hardness in the range between about 25 to about 40 on the Shore-00 durometer scale. In another embodiment, the second material can have a hardness in the range between about 40 and about 80 on the Shore-00 durometer scale. As noted above, other durometer scales could be used to measure the hardness of the second material.

[0039] In ear cover 10, the user contacting portion 30 is depicted as being formed from a single material. However, in alternate embodiments (not shown), the user contacting portion may, in fact, be formed from a combination of materials having similar properties. For example, the user contacting portion may be a laminate of materials (e.g. closed cell foam layered with a viscoelastic polyurethane foam), which may provide enhanced softness, sound attenuation, an enhanced feel, or improved hygiene (bearing in mind it will contact a user's head). Commercially available materials suitable for forming the user contacting portion 30 include a stretchy polyurethane fabric, such as spandex, or other thin elasticised fabric.

[0040] Referring now to Figures 2 and 4, the user contacting portion 30 is shown connected to an outer rim 18 of the ear encompassing portion 12. The user contacting portion 30 provides comfort to the user and is a softer material than the material of the ear encompassing portion 12. A top surface of the user contacting portion 30 contacts the user. When a user rests on the ear cover, the foam of the user contacting portion 30 is compressed, which prevents discomfort to the user's head.

[0041] The user contacting portion 30 has a groove 32, which extends around the circumference of its outer wall. An extending flange 20 of the outer rim 18 can be received within the groove 32 to retain the user contacting portion 30 in a desired position with respect to the ear encompassing portion 12. If a plate member 26 (shown in Figure 2B and described below) is present in the ear cover, the user contacting portion 30 sits on top of the plate member 26. [0042] The connection between the user contacting portion 30 and the ear encompassing portion 12 described above provides a removable assembly where no adhesive or other fasteners are required. The assembly of such an ear cover 10 is simpler and cheaper, and the serviceability of the ear cover is enhanced because parts can be readily replaced.

[0043] In an alternate embodiment (not shown), the user contacting portion 30 may not have a groove 32. In such an embodiment, the foam may have a resiliency and softness that enables it to deform in order to removably join the user contacting portion 30 to the ear encompassing portion 12.

[0044] It will be appreciated that, in alternate embodiments of ear covers in accordance with the present invention, the ear encompassing portion and user contacting portion may be provided integrally formed.

[0045] As shown in Figures 2A and 2B, the user contacting portion 30 abuts a seat 36 on the ear encompassing portion 12. The seat 36 extends around the periphery of the ear encompassing portion 12 and is raised from the base 17 of the internal cavity 16 of the ear encompassing portion 12. Internal channels 42 are provided at opposite sides of the ear encompassing portion 12 and extend laterally through it. The size of the channel 42 allows a flexible band 44 to be threaded through, as will be described below.

[0046] The ear encompassing portion 12 has an internal cavity 16. The internal cavity 16 is capable of housing an insulator, such as a foam block 24, for even greater sound insulation. The foam block 24 provides additional sound absorption properties, and may be used in situations where ambient noise is especially high. In one form (e.g. Figure 3A), the foam block 24A can be seated, connected or attached to the base 17 of the internal cavity 16. In another form (e.g. Figure 3B), the foam block 24B can be attached to the plate member 26. In a further form (not shown), the foam block 24 can sit loosely within the internal cavity 16 (e.g. if it is desirable for a user to be able to insert or remove the foam block 24 from the ear cuff to provide differing levels of sound attenuation), with the plate member 26 ensuring that the foam block 24 remains in the internal cavity 16. The plate member 26 is made of a resilient material which can be compressed for moving between the extending flange 20 and released when it abuts seat 36 so that it expands to substantially abut outer rim 18 and be incapable of being removed past the extending flange 20. In such embodiments, the block 24 need not be provided permanently affixed to the ear cover 10, but can be inserted or removed by a user for greater or lesser sound attenuation. [0047] The ear cover 10 may also have air holes 22 (see Figures 4A and 4C) to reduce excessive pressure (positive or negative) on the user's ear drums when the ear cover is being worn (as will be appreciated, the ear encompassing portion and user contacting portion cooperate to form an extremely close fit to a user's head in order to attenuate sound). Such air holes 22 cannot be too large, otherwise they will reduce the sound attenuating ability of the ear cover. The ear cover 10 generally has a low profile (i.e. it does not project very far out from a user's head when worn), smooth continuous surfaces (so that there are no "edges" which may snag on external surfaces in use) and can be substantially oval shaped (as in the Figures) or substantially rectangular shaped (not shown).

[0048] In use, two ear covers 10 can be connected by flexible bands 44, as shown in Figure 5. The bands can be made of any suitable material (e.g. a material that is comfortable to a user, will hold the ear cover(s) etc. securely in place, etc.). Suitable materials include elastic and neoprene. The band assists in maintaining the position of the ear covers 10, 10 as the user rests and substantially prevents accidental dislodgment. The bands 44 extend from one ear encompassing portion 12, when positioned on a user's ear, to another ear encompassing portion (not shown) when positioned on the user's other ear. In the embodiment shown in Figure 5, the bands 44 extend around the full circumference of the user's head. In doing so, the bands firstly connect and maintain the position of the ear covers 10, 10 and, secondly, cover the user's eyes by additionally providing an eye patch. The band is elasticised and may include a variable attachment means such as Velcro™ (e.g. at the rear of the band) to allow its length to be adjusted. The band can, in alternate embodiments, be a single strap or more than two straps. In a further embodiment, shown in Figure 6, the bands extend around the full circumference of the user's head but do not include an eye cover. Instead, the band extends above the user's forehead in a comfortable position when in use.

[0049] The ear cover 10 can be manufactured as a unitary component, or as multiple components that can be joined together to form a unitary component (thus enabling individual components to be replaceable). The manufacturing process can take a number of different forms, two of which are briefly described below. A first option can be used to manufacture an ear cover formed from a single part silicone ear encompassing portion. During manufacture, a single die cut piece can be used to form the silicone ear encompassing portion, which will result in a relatively lower assembly cost. A second option can be used to manufacture an ear cover having an ear encompassing portion formed from two parts. Whilst option 2 increases assembly costs, it would lower the tooling complexity/cost. Those skilled in the art would be capable of determining an appropriate method for manufacturing any given ear cover.

[0050] Those skilled in the art will appreciate that modifications or changes could be made to the particular embodiments exemplified herein without departing from the broad scope of the invention. All such modifications and changes are intended to fall within the scope of the appended claims.

[0051] The words "comprise", "comprising" and grammatical variations thereof, when used in this specification and in the following claims, are intended to specify the presence of the recited features, but not preclude the addition of one or more other features, integers, components, steps or groups.