CORE STRUCTURE

FIELD

[0001] The field of this invention relates generally to an earplug for insertion into an ear canal of a user, and more specifically, to an earplug that has a

resilient core structure and is capable of engaging the user's ear canal.

BACKGROUND

[0002] It is known that hearing protection devices (e.g., earplugs, earmuffs) should be used by

individuals exposed to high noise levels. It is also known that hearing protection devices can be used to inhibit water, foreign bodies, dust, or excessive wind from entering the wearer' s ear .

[0003] Currently available hearing protection devices are often uncomfortable, difficult to use, and/or perform poorly. For example, existing disposable foam earplugs, which are one known type of hearing protection device, require the user to manually compress a portion of the earplug and insert the compressed portion into their ear canal. Once inserted into the ear canal of the user, the compressed earplug is allowed to re-expand and thereby engage the user's ear canal. Foam earplugs can cause discomfort for users with relatively small ear canals in that the more compressed the earplug remains during wear, the greater the force it exerts on the user's ear canal.

[0004] Further, existing disposable foam

earplugs require the user to roll the foam between their fingers to compress it for proper insertion. If this step is not done, or is insufficiently done, the earplug is often inserted improperly so as to not provide optimal protection. Also, if the user's hands are dirty when compressing the earplug, dirt and/or germs can be transferred to the earplug and then inserted into the ear canal along with the earplug. Moreover, the earplug often rubs against the user' s ear during insertion and removal which can chafe or otherwise irritate the user's skin.

[0005] In addition, once the earplug is inserted into the ear canal, it often takes tens of seconds to re- expand and engage the user's ear canal. This delay puts the user at risk of exposure if the earplug is inserted under the circumstances from which the user is seeking protection

(e.g., a noisy environment, a windy environment) .

[0006] Moreover, existing disposable foam earplugs seal against the wall of the ear canal during use and at the moment of removal. This potentially causes a vacuum to form within the ear canal as the earplug is being removed, which can make removal difficult and/or

uncomfortable .

[0007] Accordingly, there remains a need for an earplug that is easy to use (e.g., easy to insert, easy to remove) and relatively quick to sealingly engage with the ear canal of the user when inserted. There is also a need for an earplug that facilitates insertion and removal of the earplug in a hygienic matter.

SUMMARY

[0008] In one aspect, an earplug for insertion into an ear canal of a user generally comprises a front, a back, a side extending between the front and the back, a longitudinal axis, and a transverse axis. A core structure is selectively moveable from an un-deformed position to a deformed, insertable position suitable for insertion of the earplug into the ear canal of the user. A cover covers at least a portion of the core structure and is adapted for contact with the ear canal of the user. An actuator extends outward from the back and operatively connected to the core structure for moving the core structure from the un-deformed position to the deformed, insertable position upon

application of a force to the actuator generally along the longitudinal axis.

[0009] In another aspect, an earplug for

insertion into an ear canal of a user generally comprises a front, a back, a side extending between the front and the back, a longitudinal axis, and a transverse axis. A core structure is selectively moveable from an un-deformed

position to a deformed, insertable position suitable for insertion of the earplug into the ear canal of the user. The core structure is resilient such that the core structure is biased toward the un-deformed position when in the deformed, insertable position. A cover covers at least a portion of the core structure and is adapted for contact with the ear canal of the user. An actuator is operatively connected to the core structure for moving the core structure from the un- deformed position to the deformed, insertable position.

[0010] In yet another aspect, a method of inserting an earplug into an ear canal of an ear generally comprises applying a force to an actuator of the earplug to move a core structure of the earplug from an un-deformed position to a deformed, insertable position wherein the core structure collapses to reduce a width of the earplug. The core structure is resiliently biased from the deformed, insertable portion toward the un-deformed position. The earplug is inserted into the ear canal while the earplug is in the deformed, insertable position. The actuator is released thereby allowing the bias of the core structure to move the core structure from the deformed, insertable

position to a partially deformed, inserted position wherein the earplug engages the user's ear canal.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 is a perspective of one suitable embodiment of an earplug.

[0012] Figure 2 is a front end view of the earplug of Figure 1.

[0013] Figure 3 is a right side view of the earplug .

[0014] Figure 4 is a back end view of the earplug .

[0015] Figure 5 is a perspective view of the earplug with a portion of a foam cover cut away to expose a portion of a resilient core structure.

[0016] Figure 6 is a perspective of the core structure of Figure 5.

[0017] Figure 7 is a front end view of the core structure .

[0018] Figure 8 is a right side view of the core structure .

[0019] Figure 9 is a back end view of the core structure .

[0020] Figure 10 is a perspective of the core structure in an un-deformed position. [0021] Figure 11 is a perspective of the core structure in a deformed, insertable position.

[0022] Figure 12 is a perspective of the core structure in a deformed, inserted position.

[0023] Figure 13 is a perspective of the earplug in the un-deformed position adjacent a user's ear.

[0024] Figure 14 is a perspective of the earplug in the deformed, insertable position being inserted into an ear canal of the user's ear.

[0025] Figure 15 is a perspective of the earplug in the deformed, insertable position inserted into the user' s ear canal .

[0026] Figure 16 is a perspective of the earplug in the deformed, inserted position wherein the earplug is sealingly engaged with the user's ear canal.

[0027] Figure 17 is a perspective of an earplug having another suitable embodiment.

[0028] Figure 18 is a front end view of the earplug of Figure 17.

[0029] Figure 19 is a right side view of the earplug .

[0030] Figure 20 is a back end view of the earplug .

[0031] Figure 21 is a perspective view of the earplug of Figure 17 with a portion of a foam cover cut away to expose a portion of a resiliently deformable core

structure . [0032] Figure 22 is a perspective of the core structure of Figure 21.

[0033] Figure 23 is a front end view of the core structure .

[0034] Figure 24 is a right side view of the core structure.

[0035] Figure 25 is a back end view of the core structure .

[0036] Figure 26 is a perspective of the core structure in an un-deformed position.

[0037] Figure 27 is a perspective of the core structure in a deformed, insertable position.

[0038] Figure 28 is a perspective of the core structure in a deformed, inserted position.

[0039] Corresponding reference characters indicate corresponding parts throughout the several views of the drawings .

DETAILED DESCRIPTION OF THE DRAWINGS

[0040] Referring now to the drawings, Figures 1- 5 show one suitable embodiment of an earplug, indicated generally at 10, for insertion into an ear canal of a user. As explained in more detail below, the illustrated earplug 10 is configured to sealingly engage the user' s ear canal and provide protection to the user against exposure to high noise levels. It is understood, however, that the earplug 10 can be adapted for use in inhibiting water, foreign bodies, dust, and/or excessive wind from entering the user's ear canal. [0041] The earplug 10 has a front 12, a back 14, and a side 16 extending between the front and back. The earplug 10 also has a longitudinal axis LA and a transverse axis TA (Figure 3) . In the illustrated embodiment, the front 12 and the back 14 of the earplug 10 are generally planar (i.e., flat) . It is understood, however, that the front 12 and/or the back 14 of the earplug 10 can have different configurations besides planar (e.g., concave, convex,

conical, frustum) .

[0042] As seen in Figure 3, the back 14 of the earplug 10 is wider (e.g., has a larger diameter) than the front 12. As a result, the side 16 of the earplug 10, which is generally cylindrical, tapers from the back 14 toward the front 12. It is understood, however, that the side 16 of the earplug 10 can taper in the opposite direction, i.e., from the front 12 toward the back 14. It is also understood that the front 12, the back 14, and side 16 of the earplug 10 can have substantially the same width and free from tapering.

[0043] In the illustrated embodiment, a beveled edge 18 connects the front 12 and the side 16 of the earplug 10. The beveled edge 18 facilitates insertion of the earplug 10 into the ear canal of the user. As seen in Figure 3, the beveled edge 18 of the illustrated embodiment of the earplug 10 includes a pair of angled surfaces 18a, 18b. The first angled surface 18a of the beveled edge 18, which is disposed adjacent the front 12, is wider (i.e., has a greater extent) than the second angled surface 18b. However, the second angled surface 18b, which is disposed adjacent the side 16, has a greater incline than the first angled surface 18a. It is understood, however, that the beveled edge 18 can include more or fewer angled surfaces and have other configurations (e.g., rounded, squared) . A generally rounded edge 20 connects the back 14 and side 16 of the earplug 10. It is understood, that the rounded edge 20 can have other suitable configurations (e.g., squared, angled).

[0044] With reference now to Figure 5, the earplug 10 includes a core structure, indicated generally at 30, and a cover, indicated generally at 40, covering at least a portion of the core structure. In the illustrated

embodiment, the cover 40 is a soft foam material that

completely covers the core structure. Suitably, the cover 40 is pliable, soft feeling, nonirritating and otherwise adapted for direct contact with the ear canal of the user. One suitable soft foam material for use as the cover 40 is polyurethane memory foam. It is contemplated, however, that any suitable material can be used (e.g., wool, natural rubber, silicone rubber, synthetic foam, polyimide foam, neoprene rubber, polystyrene) for the cover 40.

[0045] With reference now to Figures 6-12, the core structure 30 comprises a resiliently deformable

framework that is selectively moveable between an un-deformed position (Figure 11) and a deformed, insertable position (Figure 12) for insertion of the earplug 10 into the ear canal of the user. As seen in Figures 6-9, the core

structure 30 comprises a generally cruciform first hub 32 and a generally conical second hub 34 spaced from the first hub. A shaft, indicated generally at 36, and four beam members, indicated generally at 38, extend between and connect the first and second hubs 32, 34. As used herein, the term

"resilient" means that a material or a composite formed from more than one material has a property that permits it to be deformed in size and/or shape by application of a force and then to recover at least about 80% of its original size and shape after removal of the force causing the deformation. [0046] As seen in Figure 6, the shaft 36 has a first end 44 attached to the second hub 34, a second end 46 attached to the first hub 32, and a central passage 50 extending between its first and second ends. In the

illustrated embodiment, the shaft 36 divides into a plurality of shaft elements 42 (e.g., four shaft elements being seen in the illustrated embodiment) about a plurality of bends 48 in the shaft. As a result, each of the shaft elements 42 are spaced apart at their respective free ends and are connected to the first hub 32 at a location spaced from the center of the first hub.

[0047] Each of the four beam members 38 are substantial the same. As illustrated in Figure 6, each of the beam members 38 comprises a first beam segment 52

extending outward from and hingely connected to the cruciform first hub 32. Each first beam segment 52 includes a stem 54 having a free end 56 spaced from the first hub 32. The first beam segment is hingedly connected to a second beam segment 60 at a location near it center. Each of the second beam segments 60 are generally straight and lie at an angle relative to the longitudinal axis LA and transverse axis TA of the earplug 10 (Figure 8) . In the illustrated embodiment, for example, each of the second beam segments 60 lie at an angle a of approximately 45 degrees with respect to the longitudinal axis LA of the earplug 10. It is understood, however, that the second beam segments 60 can have different angles a relative to the longitudinal axis LA of the earplug 10. The second beam segments 60 are higedly connected to respective third beam segments 62. Each of the third beam segments 62, which are relatively short, is affixed to the second hub 34. [0048] In the illustrated embodiment, each of the hinges connecting the beam segments 52, 60, 62 is a living hinge 64 about which the respect segment can move. It is contemplated, however, that the hinges between the

segments of the beam members can be other than living hinges.

[0049] In one suitable embodiment, the core structure 30 is formed (e.g., molded) from a single piece of polymeric material. Materials suitable for the forming the core structure 30 include, but are not limited to,

polypropylene (PP) , polyethylene terephthalate (PET) ,

polyethylene (PE) , polyvinyl, polyester, and polycarbonate. It is contemplated, however, that core structure can be made from any suitable material and can be made from two or more pieces that are joined together.

[0050] With reference again to Figure 6, an actuator, indicated generally at 70, has a head 72 and a generally cylindrical post 74 extending outward from the head. The post 74 of the actuator 70 extends through an opening in the second hub 32 and the passage 50 of the shaft and into contact with an inner surface of the first hub 32. In the illustrated embodiment, the actuator 70 and, more specifically, the head 72 in combination with the post 74 are generally shaped like a golf tee. While it is understood that the actuator can have other shapes, the generally golf tee like shape of the illustrated actuator 70 facilitates manual manipulation of the actuator by the user.

[0051] As seen in Figures 10 and 11, the core structure 30 can be moved from the un-deformed position

(Figure 10) to the deformed, insertable position (Figure 11) by application of a force generally along the longitudinal axis LA of the earplug 10 (as indicated by arrow 80 in

Figures 10 and 11) to the actuator 70. More specifically, the user can manually apply the force, for example using a finger, to the head 72 of the actuator 70, which pushes the post 74 against the inner surface of the first hub 32. As a result, the post 74 causes the first hub 32 to bow slightly outward (i.e., in a direction of arrow 81) . Bowing the first hub 32 outward causes the first and second beam segments 52, 60 to pivot inward about the living hinges 64 (as indicated by direction arrows 82) towards the shaft 36 to the deformed, insertable position. The stems 54 of the first beam segments 52 are also brought inward toward the shaft 36. Once the force applied to the actuator 70 is released, the core structure, which is resilient, will return to approximately the un-deformed position of Figure 10.

[0052] Figure 12 is a perspective of the core structure 30 in a deformed, inserted position. That is, Figure 12 illustrates the position that the core structure 30 will have as inserted in the ear canal of the user. The resiliency of the core structure 30, which is trying to move the core structure back to the un-deformed position, will cause the earplug 10 to apply a force against the ear canal of the user. This force causes the earplug 10 to seal against the ear canal of the user.

[0053] In use, as seen in Figures 13-16, the earplug 10 can be inserted into the ear canal EC of the ear E of the user. Particularly, Figures 13 and 14 illustrate the user moving the earplug 10 into engagement with an outer portion of the ear canal EC. As seen in Figure 14, the front 12 of the earplug 10 is brought adjacent the ear canal such that the beveled edge 18 engages the ear canal opening. The user then pushes or otherwise applies a force to the actuator 70 to move the earplug 10 from the un-deformed position to the deformed, insertable position (Figure 15) . As described above, the core structure 30 collapses in the deformed, insertable position, which reduces the width of the earplug thereby making it easier to insert. With the earplug 10 in the deformed, insertable position, the user pushes the earplug into the ear canal EC of the ear to the desired depth within the ear canal as seen in Figure 15.

[0054] Once the earplug 10 is inserted to the desired depth, the user releases the actuator 70. Because of the resiliency of the core structure 30, the earplug 10 rapidly tries to return from the deformed, insertable

position to the un-deformed position, which applies a force against the ear canal EC of the user as illustrated in Figure 16. At this point, the earplug 10 is located in the ear canal EC of the user' s ear E in a partially deformed,

inserted position wherein the earplug is sealingly engaged with the user's ear canal. In particular, the overall shape of the earplug 10 in the partially deformed, inserted

position is partially determined by the size and shape of the user's ear canal. That is, the earplug 10 at least in part conforms to the size and shape of the user's ear canal. Once inserted in the ear canal EC, the earplug 10 will reduce the effects of noise in high noise environments.

[0055] As illustrated in Figures 13-16, the earplug 10 can be inserted in the ear canal EC of the user without the user contacting (e.g., manually grasp or

otherwise touching) the portion of the cover 40 of the earplug that is inserted. Thus, the earplug 10 can be inserted into the ear canal of the user in a hygienic manner.

[0056] Figures 17-28 illustrate another suitable embodiment of an earplug, indicated generally at 100, for insertion into an ear canal of a user. More specifically, the illustrated earplug 100 is configured to sealingly engage the user' s ear canal and provide protection to the user against exposure to high noise levels. It is understood, however, that the earplug 100 can be adapted for use in inhibiting water, foreign bodies, dust, and/or excessive wind from entering the user's ear canal.

[0057] The earplug 100 has a front 112, a back 114, and a side 116 extending between the front and back. The earplug 100 also has a longitudinal axis LA and a

transverse axis TA (Figure 19) . In the illustrated

embodiment, the front 112 of the earplug 100 is generally a hemisphere (i.e., half a sphere) . It is understood, however, that the front 112 of the earplug 100 can have different configurations besides hemispherical (e.g., planar, concave, conical, frustum) .

[0058] As seen in Figure 19, the side 116 of the earplug 100 is wider (e.g., has a larger diameter) adjacent the back 114 of the earplug as compared to the width (e.g., diameter) of the side adjacent the front 112. As a result, the side 116 of the earplug 100 tapers from the back 114 toward the front 112. It is understood, however, that the side 116 of the earplug 100 can taper from the front 112 toward the back 114. It is also understood that the side 116 of the earplug 100 can have a relatively constant width along its length or, in other words, be free from tapering.

[0059] In the illustrated embodiment, a beveled edge 118 connects the front 112 and the side 116 of the earplug 100. The beveled edge 118 facilitates the insertion of the earplug 100 into the ear canal of the user. A

generally rounded edge 120 connects the back 114 and side 116 of the earplug 100. It is understood, that the beveled edge 118 and rounded edge 120 can have other suitable

configurations . [0060] With reference to Figure 21, the earplug 100 includes a core structure, indicated generally at 130, and a cover, indicated generally at 140, covering at least a portion of the core structure. In the illustrated

embodiment, the cover 140 is a soft foam material that completely covers the core structure. Suitably, the cover 140 is pliable, soft feeling, nonirritating and otherwise adapted for direct contact with the ear canal of the user.

[0061] With reference now to Figures 22-28, the core structure 130 comprises a resiliently deformable

framework that is selectively moveable between an un-deformed position (Figures 22 and 26) and a deformed, insertable position (Figure 27) for insertion of the earplug 100 into the ear canal of the user. As seen in Figures 22-25, the core structure 130 comprises a generally cylindrical first hub 132 and a generally tubular second hub 134 spaced from the first hub. A shaft, indicated generally at 136, extends from the first hub 132 and through a passage in the second hub 134. Three beam members, indicated generally at 138, extend between and connect the first and second hubs 132, 134.

[0062] In the illustrated embodiment, the shaft

136 has a generally bulbous first end 144 that is spaced outward from the second hub 134 and a second end 146 attached to the first hub 312. As seen in Figure 22, the shaft 136 includes a passage 135 and three longitudinal slots 137 (only one slot being shown in Figure 22) in communication with the passage .

[0063] Each of the three beam members 138 are substantial the same and comprises a first beam segment 152 extending outward from and hingely connected to the first hub 132. Each first beam segments 152 is generally straight and lies at an angle a relative to the longitudinal axis LA of the earplug 10 (Figure 24) . The first beam segment 152 is hingedly connected to a second beam segment 160 at its end spaced from the first hub 132. Each of the second beam segments 160, which are generally straight, is higedly connected to the second hub 34.

[0064] In the illustrated embodiment, each of the hinges connecting the beam segments 152, 160 is a living hinge 164 about which the respect segments can move. It is contemplated, however, that the hinges between the segments of the beam members can be other than living hinges.

[0065] An actuator, indicated generally at 170, has a head 172, a generally cylindrical post 174 extending outward from the head, and three fins 175 connected to the post. The post 174 of the actuator 170 extends into the passage 135 of the shaft 136 and each of the fins 175 extend through one of the slots 137 in the shaft 136 and operatively connect the actuator 170 to the second hub 132.

[0066] The core structure 130 can be moved from the un-deformed position (Figure 26) to the deformed,

insertable position (Figure 27) by application of a force generally along the longitudinal axis LA of the earplug 100 (as indicated by arrow 180 in Figure 26) to the actuator 170. More specifically, the user can manually apply the force, for example using a finger, to the head 172 of the actuator 170, which pushes the post 174. As a result, the post 174 moves within the passage 135 of the shaft 136 towards the first hub 132. Movement of the post 174 causes the fins 175 and the second hub 134, which are connected to the fins through the slots 137 in the shaft 136, to also move toward the first hub 132, as indicated by arrow 182. [0067] As seen in Figure 27, the movement of the second hub 134 causes the first and second beam segments 152, 160 to pivot inward about the living hinges 164 (as indicated by direction arrows 184) towards the shaft 136 to the

deformed, insertable position. Once the force applied to the actuator 170 is released, the core structure 130, which is resilient, will return to approximately the un-deformed position of Figure 26.

[0068] Figure 28 is a perspective of the core structure 130 in a deformed, inserted position. That is, Figure 28 illustrates the position that the core structure 130 will have when inserted in the ear canal of the user. The resiliency of the core structure 130, which is trying to move the core structure to the un-deformed position, will cause the earplug 100 to apply a force against the ear canal of the user. This force causes the earplug 100 to seal against the ear canal of the user. Once inserted in the ear canal EC, the illustrated earplug 100 will reduce the effects of noise in high noise environments.

[0069] When introducing elements of the present invention or the preferred embodiment ( s ) thereof, the

articles "a", "an", "the", and "said" are intended to mean that there are one or more of the elements. The terms

"comprising," "including", and "having" are intended to be inclusive and mean that there may be additional elements other than the listed elements.

[0070] As various changes could be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.